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. |
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Water drainage holes must remain clear. |
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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). |
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Cavity sealing, rear lid |
| |
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Cavity sealing, bonnet |
| |
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Cavity sealing, door |
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 ...
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:
Removing and installing Denso belt pulley
Note
The pulley is sensitive to impact and should therefore be
treated with extreme care.
If the belt pulley overload protection has deployed, check
freedom of movement of air conditioner compressor before
rene ...
Temperature switch for evaporator -E33
Function:
The temperature switch for evaporator -E33- senses the
temperature between the cooling fins of the evaporator. It
prevents the possibility of ice forming between the evaporator
cooling fins by interrupting the current to the ai ...
Removing and installing heat shield for centre exhaust system
Note
The removal and installation procedures may have to be modified
slightly depending on engine fitted.
Removing
–
Removing rear exhaust system
→ Rep. gr.26.
–
Loosen lock washers -2-.
...
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Corrosion protection measures for wing surface in contact with wheel housing
liner
Corrosion protection for body components, add-on components and welded
components