VW Golf manuals

Volkswagen Golf Service & Repair Manual: Notes on treating corroded fold areas

Examples for corrosion in the fold area of bonnet, door or rear lid
–  Remove corrosion using → Chapter „Pneumatic brush grinder set -VAS 6446-“ or → Chapter „Brush grinder set -VAS 6776-“.
–  Smooth off transitions using sandpaper (P360 to P400 grade).
–  Clean substrate using silicon remover.
–  After a corrosion damage has been repaired and before sealing, isolate substrate using 2-pack wash primer -LHV 043 000 A2-, and then apply 2-pack HS Performance surfacer.
–  As soon as the surfacer is completely dry, treated areas must be dry-sanded using P400 to P500 sandpaper. When sanding, take particular care not to “sand through”. Afterwards, clean sanded surfaces with silicon remover.
–  After sanding the dry surfacer, the metal edges in the fold area must be sealed with fine seam sealant → Chapter „Sealing materials“. Ensure that the fine seam seals are identical in appearance to the original seam seals, as specified in the → »Vehicle-specific paintwork information« for the particular vehicle.
  Note
  Seam seals made during repair work must be identical in appearance and thickness to the original seam seals.
  To avoid damage or faulty operation, brush seam seals smooth near attachments which must be attached.
  Water drainage holes must remain clear.
  All threaded studs and welded nuts with metric threads as well as all other studs and contact surfaces for assembly must be functional following the extent of the sealing work.
  Sealant must never be applied to bare metal. Substrates must always be coated with surfacer first.
–  Restore paintwork structure according to the paintwork repair manual.
–  Apply cavity sealant along entire fold area using → Chapter „Suction feed spray-gun -V.A.G 1538-“; → Chapter „Anti-corrosion materials“.
  Note
The repair can only be considered successful if the fold area is sealed air-tight from inside (so that no ingress of moisture is possible).
   
   

Cavity sealing, rear lid
Cavity sealing, rear lid

   

Cavity sealing, bonnet
Cavity sealing, bonnet

   

Cavity sealing, door
Cavity sealing, door

Corrosion protection measures for wing surface in contact with wheel housing liner
  Note   The corrosion protection measure is to be carried out in the groove of the wing of all new replacement parts which have not had the additional sealant applied ...

Corrosion protection for body components, add-on components and welded components
Attachments   Wings, doors, covers and flaps must be coated completely on the inside as well. One wet-in-wet spray pass is adequate for ...

Other materials:

Switching the front passenger front airbag on and off manually using the key-operated switch
Fig. 72 In the dash panel on the front passenger side: key-operated switch for switching the front passenger front airbag on and off First read and observe the introductory information and safety warnings The front passenger front airbag must be switched off when securing a rear-facing c ...

Removing and installing temperature flap control motor -V68-, LHD vehicles
Heater and air conditioning system with electric/manual controls Special tools and workshop equipment required Vehicle diagnostic tester Removing –  Switch ...

Overview of fitting locations - components not located in passenger compartment, Golf Variant LHD
1 -  Exhaust ventilation for passenger compartment Checking → Chapter Removing and installing → Chapter 2 -  Humidity sender for air conditioning system -G260- Check v ...

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