Workshop Manual Transporter 2016 23-29

Service
General InformationBody Repairs,

General Body Repairs
Edition 12.2016
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Service Department. Technical Information

Service
Repair Group
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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2017 Volkswagen AG, Wolfsburg D4B807E3B5B

General InformationBody Repairs, General Body Repairs - Edition 12.2016
Contents
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1 Safety Instructions . . . . . . . . . . . . . . . . .d.by. V. . . . . . . . . . . . . . . . . . . . . . . . .t g.u.ar. . . . . . . ... 1
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1.1 Part removal . . . . . . . . . . . . . . . . . .th.or.is. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .nt.ee.o. . . ... 1
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1.2 Battery and welding operation . . s.s a. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .r a.c . ... 1
1.3 Electronic control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1.4 Paint, glass, soft pad and trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
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1.5 Fuel tank or fuel delivery pipeline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
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1.6 Air conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
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1.7 Airbag system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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1.8 Check the seat belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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1.9 urposes, in part or in wh
Safety specifications for the seat belt tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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1.10 Body repair on a vehicle equipped with the seat belt tensioners . . . . . . . . . . . . . . . . . . . . 6
1.11 Perform cutting off, correcting and/or levelling on a vehicle equipped with airbags . . . . . . 8
1.12 Remove the front seats with a side airbag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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2 Basic instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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2.1 Diagnosis of the accident vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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2.2 Condition of the body and/or the parts for delivery to the painting workshop . . . . . . . . . . . . 9
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2.3 Correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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2.4 Cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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2.5 Body-cut part and part section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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2.6 Original connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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2.7 Galvanized body parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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2.8 Remove the rest part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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2.9 New parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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2.10 Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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2.11 Moulded foam plastic pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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3 Symbolic interpretation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.1 Symbolic interpretation for welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.2 Symbolic interpretation for the operation method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4 Body repair tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.1 Flaring tool V.A.G 1317 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.2 Punching pliers V.A.G 1329 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.3 Basic equipment V.A.G 1366/3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.4 Bottom protection layer spray gun V.A.G 1379 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.5 Electric blower V.A.G 1416 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.6 Door tensioner V.A.G 1438 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.7 Body equipment component V.A.G 1439 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.8 Pneumatic cutting knife V.A.G 1523 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.9 Air chisel V.A.G 1577 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.10 Edge closing iron block V.A.G 1585 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.11 Welding fume ventilator V.A.G 1586 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.12 Welding spot releasing device V.A.G 1731 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.13 Pneumatic spray gun V.A.G 1761/1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.14 Pneumatic punching and thinning pliers VAS 1996 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.15 Pneumatic adhesive spray gun V.A.G 2005 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.16 Door hinge correction tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.17 Hose kit 5023 for the inert gas protection welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.18 Angle grinder VAS 5174 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.19 Angle grinder VAS 5175 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.20 Wire brush VAS 5182 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5 Body bonding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.1 Transporter 1991 → . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.2 Bonding types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.3 Repair method for replacing the parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Contents i
6 Corrosion protection measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

6.1 Corrosion protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
7 Waste disposal instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
7.1 Waste disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
7.2 Air pressure tappet exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
7.3 Airbag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
8 Contact corrosion protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
8.1 Connection of aluminium alloy/magnesium alloy with steel . . . . . . . . . . . . . . . . . . . . . . . . 25
9 Steel plate repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
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9.1 High-strength body plate . . . .k.sw. a.g.en. A. G. . . . . . . . n. A. G. d. o.e.s n. . . . . . . . . . . . . . . . . . . . . . . . . . 26
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9.2 Galvanized body parts . d. b.y.V. . . . . . . . . . . . . . . . . . . . . . . .t g. u.ar. . . . . . . . . . . . . . . . . . . . . . 26
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9.3 Welding on the galvanized ris body steel plate . . . . . . . . . . . . . . . .nte. e. . . . . . . . . . . . . . . . . . . 27
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9.4 Tearing test . . . .ss.a. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .a.c . . . . . . . . . . . . . . . . 28
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10 Aluminium repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
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10.1 Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
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10.2 Surface treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
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10.3 Levelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
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10.4 Temperature control for heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
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11 Plastic repair method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
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11.1 Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
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11.2 Repairing the pit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
11.3 Repairing the scratch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
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11.4 Repair the crack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
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11.5 Repairing the small hole (the diameter is more than 30 mm) . . . . . . . . . . . . . . . . . . . . . . . . 36
11.6 Plastic repair (glass fibre material) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
11.7 Repair process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
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12 Glass repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
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12.1 Repairing the windshield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . tion in

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ii Contents
1 Safety Instructions
(Edition 12.2016)
1.1 Part removal

Before the gravity centre position of the vehicle changes greatly
due to the removal, the vehicle must be securely fixed on the lifting
platform.
1.2 Battery and welding operation
Note
Before disconnecting the battery grounding, first obtain the code

of the radio. Before handing over the vehicle to the customer,
make the radio ready for playing through entering the correct
code.
Before carrying out any welding, always disconnect the two ter‐
minals of the battery, and then cover the two poles of the battery.
satelettronica
Before carrying out any operation producing possible sparks near
the battery, always remove the vehicle battery.
WARNING
Switch on the ignition before connecting the battery!

When the battery is connected, do not allow anyone in thenve‐
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1.3 Electronic control unit
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The grounding terminal of the welding machine is directly con‐
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nected to parts to be welded. In addition, there shall be no
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electrical insulation part between the grounding terminal and the ab

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The electronic control unit and the electrical wire are not allowed
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1.3.1 Processing of the electronic control unit

after repair due to a traffic accident
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After the traffic accident occurs, change of the electric control unit
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will not be necessary until there is at least one of the following

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♦ The housing is significantly deformed or damaged.

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♦ The instrument appearance is not damaged, but the bearing

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♦ The plug connection is damaged or rusted due to moisture.

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♦ The functional check or unit self-diagnosis procedure may

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If an electronic part is removed as required by the service oper‐ p by
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1. Safety Instructions 1
1.4 Paint, glass, soft pad and trim

Other vehicles under no protection are not allowed to be parked
in the operation area for the body repair. (There is a risk of fire
due to spark, battery, paint and damaged glass). en AG. V
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1.5 Fuel tank or fuel delivery pipelineed
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An extreme care shall be exercised in caseau that grinding and
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welding operations are carried out in the
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delivery part area. These parts must be removed in case of po‐
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1.6 Air conditioner
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After refrigerant is added into the air conditioner, its components
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are allowed to be neither welded, nor brazed or soldered. If there
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is a risk to heat the air conditioner components during welding
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and soldering on the vehicle, welding is not allowed either. In term
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of paint repair, temperature of the object in the drying oven or the
preheating area is only allowed to reach 80°C, as there will be a
large overpressure in the heated equipment, which may cause an
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equipment burst.
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Note
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In case that welding is performed near the refrigerant hose, it is
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also necessary to withdraw the refrigerant in the refrigerant circuit.
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Invisible ultraviolet will be released during welding, and they may

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infiltrate into the refrigerant hose and break down the refrigerant.
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1.6.1 Remedial measures:

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Suck the refrigerant circuit ⇒ heater and air conditioner; Rep. gr.
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The drained air conditioner may only be filled in a maintenance
shop equipped with special V.A.G equipment. In case of required
safety measures, the equipment must be turned on to drain the
refrigerant.
If necessary during repairing the vehicle, drain the refrigerant cir‐
cuit, and avoid contact with the refrigerant or the refrigerant
vapour!
Wear rubber gloves and goggles to protect your hands and eyes!
The reason is that refrigerant spilt onto the unprotected human
body parts may cause a frostbite in a serious situation.
WARNING
It is suggested to prepare a rinsing bottle for flushing your eyes.

If liquid refrigerant enters your eyes, rinse immediately with
water for 15 minutes.
Then wash your eyes with eye drop, and go to see an oph‐
thalmologist right away even if your eyes do not hurt. You must
tell the doctor that the frostbite is caused by refrigerant R12 or
R134a.
If the refrigerant is still in contact with other parts of the body
even though the safety measures are followed, these areas
also need to be thoroughly rinsed with cold water immediately
for at least 15 minutes.
Although refrigerant causes no fire risk, smoking is not allowed in

a room where the refrigerant is placed. The reason is that a lit
2 1. Safety Instructions
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General InformationBody sRepairs,
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cigarette has a hightemperature which may cause
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composition of the refrigerant gas. Inhalation of the toxic decom‐
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position generated by this will result in an irritable cough and
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1.7 Airbag system
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Repair instructions ⇒ internal body repair; Rep. gr. 69 .
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During operation on the airbag system as well as correction op‐
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eration within the body repair scope, the battery grounding must
be disconnected.
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WARNING
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When the battery is connected, do not allow anyone in the ve‐
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The temperature of the airbag components must not exceed 100°

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C, not even instantaneously.

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The airbag components are not allowed to come into contact with
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The mechanically damaged airbag components must be re‐ py by
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placed. =>Disposal instructions ⇒ page 23 .
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Prote AG.
After coming in to contact with a triggered airbag unit, wash your
hands!
1.8 Check the seat belts
WARNING
Systematically check the seat belt system every time after an

accident! If one item is found damaged according to the items
to be checked, the customer must be informed of the necessity
to replace the seat belt.
Items to be checked:
♦ Belt body
♦ Automatic retractor (locking function)
♦ Visual inspection of the seat belt buckle
♦ Seat belt buckle function
♦ Seat belt guide member and tongue
♦ Fixing piece and fixing point
♦ Automatic waist seat belt retractor
Note
If the customer refuses to replace a damaged seat belt, corre‐

sponding notes must be made.
1.8.1 Belt body

– Pull the seat belt completely out of the automatic seat belt re‐
tractor or the waist seat belt adjuster.
AG. Volkswagen AG d
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General InformationBody Repairs, General Body Repairs - Edition 12.2016 s
ce
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nl
pt
du
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– Check that whether the seat belt is dirty, and if necessary,
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clean it with neutral soap solution=>see the instructions for
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• If one of the damages (1 and 2) indicated in the following is
hole
confirmed on a traffic accident vehicle, replace the seat belt
spec
together with the seat belt buckle.
es, in part or in w
t to the co
• Even there is no accident, the damaged seat belt must be re‐
placed if there is any confirmed damage as shown in the
following 1, 2 or 3.
rrectness of i
1-The belt body is cut, torn or scratched.
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nform
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ate
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2-The fabric on the belt edge is torn.
AG.
3-There are burns by cigarettes and the like.
1.8.2 Automatic retractor (locking function)

The automatic seat belt retractor has two locking functions.
♦ The first locking function is triggered when the seat belt is
quickly extracted from the automatic seat belt retractor (belt
extraction acceleration).
Checking
– Vigorously pull the seat belt out of the automatic retractor.
• No locking function-replace the seat belt together with the seat
belt buckle.
General InformationBody
AG. Volkswagen ARepairs, General Body Repairs - Edition 12.2016
n G do
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Volks ot g
• If the seat belt extractioned by or retraction function does not work, ua
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first check that whether
horis the automatic seat belt retractor is in ntee
the correct position.
au
t or
ac
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• The second locking function is triggered through change of the
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vehicle operation process (locking function associated with the
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vehicle).
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Checking
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– Fasten the seat belt.
hole
spec
– Accelerate the vehicle to 20 km/h, and then perform an emer‐
es, in part or in w
t to the co
gency braking using the foot brake.
• If the seat belt is not locked by the locking mechanism during
the braking process, replace the seat belt together with the
rrectness of i
seat belt buckle.
l purpos
WARNING
nform
ercia
For safety reason, this driving test shall be performed on a road

m
a
segment without other running vehicles, in order to avoid pos‐
com
tion in
ing a danger to the other road users.
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1.8.3 Visual inspection of the seat belt buckle
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– Check whether there is cracking and peeling in the seat belt
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• Replace the seat belt together with the seat belt buckle in case cted agen
Prote AG.
of damage.
1.8.4 Seat belt buckle function

Check the seat belt locking mechanism:
– Push the tongue into the seat belt buckle till you hear the en‐
gagement sound. Vigorously pull the seat belt to check wheth‐
er the closing mechanism locks.
• Even there is only one locking failure of the tongue in the seat
belt buckle for over 5 inspections, the seat belt must be re‐
placed together with the seat belt buckle.
Check the unlocking mechanism:
– Use your finger to press the button on the seat belt buckle to
release the seat belt. When the belt body is released, the
tongue must automatically come out of the seat belt buckle.
• Check for least 5 times. As long as the latch does not pop out
for at least one time, replace the seat belt together with the
seat belt buckle.
WARNING
it is not never permissible to use lubricant on the button of the

seat belt buckle to eliminate the noise or blockage in case of
the seat belt operation.
1.8.5 Seat belt guide member and tongue

After the seat belt system is stressed (when the seat belt is dam‐
aged in an accident), there will be some small parallel clefts on
the guide member with a plastic coating. (This is different from the
wear often seen, and the latter shows smooth wear without fine
patterns).
– Check the plastic materials for deformation, peeling and crack‐

ing.
• Replace the seat belt together with the seat belt buckle in case
of clefts and/or damages.
1.8.6 Fixing piece and fixing point

♦ The fixing strip/bracket is deformed (stretched).
♦ The height adjustment device does not work.
♦ Fixing points (seat, door post or vehicle floor) are deformed or
the threads are damaged.
• Replace the seat belt together with the seat belt buckle in case
of damage found on these parts.
• Replace the fixing points.
Note
For damage (such as wear) not caused by a traffic accident, only

replace corresponding damaged parts.
satelettronica
G. Volkswagen nA AG do
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1.9 Safety specifications for the seat belt ris
ed
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tensioner s tho
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♦ Test, removal, installation and maintenance shall only be per‐
le
un
pt
formed by trained personnel.
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♦ Blasting ignition material has no expiration date, and that is to
pe
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say it may be kept without time limit and requires no mainte‐
ot
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nance.
h re
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♦ The components of the seat belt tensioner are allowed to be

spec
es, in part or in w
neither opened nor repaired; only new components may be

t to the co
used in principle.
♦ A seat belt tensioner unit falling to the ground is not allowed
to be reinstalled in the vehicle.
rrectness of i
♦ In case of mechanical damage (buckling deformation and

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crack) to the seat belt tensioner, it must be replaced.

♦ The tensioner unit must be installed immediately after it is tak‐
nform
ercia
en out of the shipping container.

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com
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♦ When the work is interrupted, the seat belt tensioner unit shall
on in
be put back into the shipping container.

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♦ Do not randomly place the seat belt tensioner unit.

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♦ Do not use grease, cleaning agent or similar media to process

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the seat belt tensioner unit, and do not expose it to a temper‐
Co
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ature higher than 100°C, even if the period is very short. ht. rig
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1.10 Body repair on a vehicle equipped with
by c lksw
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the seat belt tensioners
WARNING
Before cutting off, correcting and/or levelling, you must remove

a mechanical blasting seat belt tensioner without the wearing
identification function (trigger lock). The battery grounding
must be disconnected for an electric blasting seat belt tension‐
er.
Note
If the seat belt is completely retracted, in case of an accident, the

wearing identification device (trigger lock) will hinder triggering of
the mechanical blasting seat belt tensioner.
WARNING
During cutting off, correcting and/or levelling, do not pull out

the seat belt for the seat belt tensioner with a wearing identifi‐
cation device. In case of a large vibration caused during cutting
off, correcting and/or levelling, you must also remove the seat
belt tensioner with a wearing identification device.
There is no wearing identification device on the vehicle seat belt

tensioners listed below:
• Golf 1992 →
• Golf Cabriolet 1994 →
satelettronica
• Passat 1988 →
• Passat 1994 →
• Polo 1995 →
• Polo Classic 1996 →
• Polo Wagon 1998 →
Disassemble and install the seat belt with a tensioner ⇒ internal
body repair; Rep. gr. 69 .
1.10.1 The following vehicles have been equip‐ lkswage

n AG. Volkswagen AG do
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ped with: se
d by Vo ua
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tho or
Mechanical seat seat Electric
au ac
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belt tensioner with a belt tensioner
ce
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wearing identifica‐
un
pt
an
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tion device
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Passat 1997 → front and X ab

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Golf 1998 → front with X
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side airbags
spec
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Golf 1998 → front without X

t to the co
side airbags
New Beetle 1999 → front X
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with side airbags

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with side airbags (only

the first year model in
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America)
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without side airbags

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Lupo 1999 → front X

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Transporter 1991 → front X

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(since the year 1998

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LT 1997 → front X
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1.11 Perform cutting off, correcting and/or

levelling on a vehicle equipped with air‐
bags
During operation on the airbag system as well as correction op‐
eration within the body repair scope, the battery grounding must
be disconnected.
WARNING

When the battery is connected, do not allow anyone in the ve‐
hicle!
AG. Volkswagen AG d
agen oes
olksw not
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Repair instructions ⇒ internalisebody
db repair; Rep. gr. 69 . ara
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1.12 Remove the front seats with a side air‐ ss au ra
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WARNING
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In case of removing the front seats, be sure to follow the safety
h re
hole
instructions.
spec
es, in part or in w
t to the co
The safety instructions may be obtained from the repair manual
of corresponding models ⇒ internal body repair; Rep. gr. 69 .
rrectness of i
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ate
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2 Basic instructions
2.1 Diagnosis of the accident vehicle

In case of the accident vehicle repair, the occasionally undiscov‐
ered damage on the chassis and the unit suspension may cause
serious damage in future. In case of a traffic accident, this means
that the vehicle has borne a high load, and therefore do not only
check axles, but also pay attention to the following parts:
♦ Determine whether the functions of the steering system and
the steering tie rod are normal through checking the steering
angle. Visually check for bending or cracking.
♦ Check the chassis and all chassis components, e.g. swing
arm/longitudinal control arm, shock strut, steering knuckle,
stabilizer bar, secondary beam, axle body and their fixing
pieces for bending or cracking.
♦ Check the rims and the tyres for damage extent, radial run-out
and unbalance degree. Check the tyre pattern depth and the
tyre side, and check the tyre inflation pressure.
satelettronica
♦ Check the suspension devices for the engine, the gearbox, the
axles and the exhaust device for damage.
♦ In the end, perform a proper trial driving after the repair, in
order to ensure traffic safety and good mechanical Acondition
G. Volkswagen AG d
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of the vehicle for delivery to the customerVowithout
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2.2 Condition of the body and/or the parts tho
rise tee
or
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for delivery to the painting workshop ss ac
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nl
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Before delivery of the repaired vehicle or the individual parts to
du
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the painting workshop, sandpapers of a grit size P80 to P100 must

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be used to grind the repaired or corrected as well as scraped (if
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necessary) surface as a preparation for the subsequent painting.

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This preparation falls into the work scope of the sheet metal work‐ h re
hole
spec
shop, and is included in the repair period.
es, in part or in w
t to the co
2.3 Correction
During batch production, the body and the underbody device are
rrectness of i
mainly made of the cold-deformed deep-drawn steel plate. For

this reason, recovery deformation for the accident damage is car‐
l purpos
ried out in the same way.

If recovery to the shape before the accident fails due to a serious
nf
ercia
damage, the damaged part shall be cut off after the connection is
orm
corrected.
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2.4 Cutting
or
thi
te
sd
iva
The cutting influencing the body structure strength and then af‐
o
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fecting the vehicle driving and traffic safety must be carried out
o
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f
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following relevant repair manual.

t.
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2.5 Body-cut part and part section

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This“Cut Part”is interpreted as cutting for an individual part (e.g.
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Prote AG.
sharp front and rear ends), and the cut part is provided by the part
warehouse.
– On the contrary,“Part Section”is to be cut from the part itself.
Operation shall be carried out by strictly following the way de‐
scribed and illustrated in the body repair manual in a specific
situation.
2. Basic instructions 9
– Since using“Cut Part”or“Part Section”as well as applying

which special tool will influence the period, various tools and
equipment are described separately in the repair manual.
2.6 Original connection

“Original Connection”is interpreted as welding connection adop‐
ted for vehicle manufacturing.
The welding connection positions shall be recovered during the
body repair.
Make sure that the welding spots in case of repair are no less than
the welding spots in the batch production.
The methods and processes different from the original connection
are described in relevant body repair manual.
2.7 Galvanized body parts

With use of the fully galvanized steel plates, the body is already
of a high corrosion resistance in the frame production phase. In
order to maintain the performance of anti-penetration rust, make
sure to follow ⇒ page 26 the operation procedures in the repair
instructions.
satelettronica
WARNING
. Volkswag
Since there is toxic zinc woxide
agen in the welding
AG en AG
fume
does arising from
Volks steel plates, a good ventilation
welding of the galvanized not
gu in the
by ara
operation siterimust
se
d be provided, and a proper smoke ventilator
nte
(such as -V.A.G
au
tho 1586- ) shall be used to discharge the smoke. eo
ra
ss c
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le
un
pt
2.8 Remove the rest part

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If the damaged body part will be roughly cut off according to the
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cutting position in relevant repair manual, e.g. using body saw -

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is n
h re
V.A.G 1523- , most spot welding connections shall be drilled out

ole,
using welding spot releasing device - V.A.G 1731- .

spec
In addition, it is suggested to use flat-grinding machine -

t to the co
V.A.G 1529- and angle grinder, in order to remove the welding

spot connections which may not be removed by the welding spot
releasing device.
rrectne
2.9 New parts

ss o
cial p
For the new parts e.g.: Lower edge beam which may not be ac‐
f in
cessed from the interior after the repair, due to the corrosion
form
mer
prevention requirement, consistent paint with the vehicle colour

atio
m
shall be sprayed on its cavity before welding. It is suggested to

o
n
c
cover the welding connection positions using adhesive tapes at

i
or
n thi
this time.
te
sd
iva
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2.10 Parts
um
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fo
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ng
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Due to reduction of the stock part categories, the provided parts
. Cop py
are usually of“basic models”.
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For example:
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cted agen
Prote AG.
• There is no hole for the trim or the antenna in the fenders of
Golf 1984→1991.
• There is no hole for the rear windshield wiper or the interior
panel in the rear trunk lid of Transporter 1991→.
In this case, it is suggested for the repair shop to make
a“template”using the damaged part.
10 2. Basic instructions
Such as holes for for the rear windshield wiper in the rear trunk
lid of Transporter 1991→:
• Use body saw -V.A.G 1523- to cut off a part of the trunk lid,
and pay attention to the significant contour at this time. For the
VW emblem notch and the upper wiper hole edge as exam‐
ples, remove the burrs of the side cut, and use fabric-rein‐
forced adhesive tapes for protection.
Before painting the new parts and in case of installing the module
and marking the holes to be drilled, you must pay attention to the
material strength of the module.
Before delivering the parts (such as doors, engine compartment
baffle/rear trunk cover or fenders) to the painting workshop,
please check for transportation damage. If transportation damage
or other damages are found in case of assembly, this may avoid
a repeated painting.
2.11 Moulded foam plastic pads

These moulded parts are installed in the body manufacturing
process, and their volumes begin to grow from about 180°C in the
drying oven in the painting workshop.
satelettronica
Use the moulded foam plastic pads in the following methods:
– Remove the residual foam from the vehicle.
– Restore the paint structure. If necessary, use glass primer -
DCN 009 200 02- to brush twice (the second coat gen may
AG. Vobe
lkswagen AG
does
applied in the opposite direction)-the airdry ol swa shall be at
ktime not
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least 10 minutes. ed
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Conditions aut or
ac
ss
– Before starting these work steps, ensure that the parts for re‐
ce
le
un
pt
placement must be ready though preparation, such as cutting,
an
d
itte
adjustment and corrosion protection measures.

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Replace the moulded foam plastic pads
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– Apply seal - AKD 497 010 04 R10- around the moulded foam
h re
hole
plastic pads. spec

es, in part or in w
– Install the moulded foam plastic pads in corresponding posi‐

t to the co
tions of the vehicle.

– Fix the new parts (such as column A) in the mounting posi‐
rrectness of i
tions. Gently press the new parts in the moulded foam plastic
pad area till a close contact is achieved, and then weld them.
l purpos
– Inert gas protection welding (SG) must not be used within 15

mm from both sides of the moulded foam plastic pads.
nform
ercia
– After the vehicle is painted, use the inner cavity spray wax -
m
a
com
DCN 330 KD2 Z1- to carry out anti-corrosion treatment in the

ion in
repair area.
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Prote AG.
2. Basic instructions 11
3 Symbolic interpretation
3.1 Symbolic interpretation for welding
RP resistance pressure spot weld (single row) RP = resistance
pressure spot welding
RP resistance pressure spot weld (double rows)
RP resistance pressure spot weld (double staggered rows)
SG inert gas protection plug weld SG = inert gas plug welding
SG inert gas protection spot welding

SG full inert gas protection weld
SG discontinuous full inert gas protection weld
. Volkswag AG en AG
agen does
Brazing ksw not
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3.2 Symbolic interpretation for the operation

hole
spec
method
es, in part or in w
t to the co
rrectness of i
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orm
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or c
thi
te
3.2.1 Grinding
sd
iva
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– Use an angle grinder to remove the material adhering to the

en
ng
t.
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weld.
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by c lksw
Note Prote
cted AG.
agen
Try not to reduce the thickness of the outer plate in case of grind‐
ing the weld, but a slight reduction is allowed.
12 3. Symbolic interpretation
lkswage es n
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byV General InformationBody ua Repairs, General Body Repairs - Edition 12.2016
d ran
ir se tee
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u or
3.2.2 ss
a
Thinning ac
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– The purpose is to carry out overlap welding.
du
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itte
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ility
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hole
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es, in part or in w
t to the co
rrectness of i
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nform
mercia
at
om
ion
c
in t
or
his
ate
do
riv
3.2.3 Punching
p
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or
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f
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ng
t.
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– Drill in the new parts for carrying out subsequent inert gas
Co
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protection plug welding. t. C rig
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pyri by
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Prote AG.
3.2.4 Drilling
– Drill out the welding spots for carrying out subsequent inert
gas protection plug welding or resistance pressure spot weld‐
ing (original connection).
3. Symbolic interpretation 13
AG. Volkswagen AG d
agen oes
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3.2.5 Polishing d by
Vol not
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ara
ise nte
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♦ Use wire brush -VAS 5182- to remove uthe t paint in the not
ho eo
ra
easily accessible areas (such as the sinside
s a
of the roof frame). c
ce
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un
pt
an
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t to the co
3.2.6 Cavity corrosion protection
rrectness o
cial p
f inform
mer
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satelettronica
i
or
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te
sd
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3.2.7 Bonding
p by
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Prote AG.
3.2.8 Precise sealing
14 3. Symbolic interpretation
4 Body repair tools
Note
The following tools are listed according to V.A.G/VAS serial num‐

bers.
4.1 Flaring tool -V.A.G 1317-
AG. Volkswagen AG d
agen oes
lksw not
satelettronica
Vo gu
by ara
d
ise nte
4.2 Punching pliers -V.A.G 1329- or eo
th
au ra
ss c
♦ Punching the parts before welding
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
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wit
is n
h re
ole,
spec
t to the co
rrectne
4.3 Basic equipment -V.A.G 1366/3-
ss o
♦ Body correction tool provided together with the correction
cial p
f i
frame
nform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
cum
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fo
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t. rig
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by
cted agen
4.4 Bottom protection layer spray gun -
Prote AG.
V.A.G 1379-
♦ Spraying the bottom protection layer paint
4. Body repair tools 15

4.5 Electric blower -V.A.G 1416-

♦ Releasing the frozen locks, trunk lid and doors
♦ Drying the ignition and illuminating systems
♦ Heating the fenders for their easier removal from the body
♦ Drying the body interior without removing the surface skin
♦ Accelerating the adhesive drying
♦ Remove the adhesive on the body and the windshield surface
more quickly and easily
4.6 Door tensioner -V.A.G 1438-

♦ During body repair, ensuring a correct door gap, and also used
as an auxiliary tool in case of welding of different steel plate
materials
satelettronica
lkswage es n
o ot g
yV
4.7 Body equipment component - ir se
d b ua
ran
tee
V.A.G 1439- tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
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erm
ab
ility
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wit
is n
h re
ole,
spec
t to the co
rrectne
4.8 Pneumatic cutting knife -V.A.G 1523 A-

♦ Used for cutting the body material
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
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co lksw
by
cted agen
Prote AG.
16 4. Body repair tools

4.9 Air chisel -V.A.G 1577-
4.10 Edge closing iron block -V.A.G 1585-

♦ Used for closing the curved weld during the body repair
satelettronica
4.11 Welding fume ventilator -V.A.G 1586-
agen
AG. Volkswagen AG d
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olks ot g
byV ua
ed ran
ris tee
tho or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
4.12 Welding spot releasing device -
V.A.G 1731-
rrectness of i
♦ Releasing the welding point connection during the body repair

l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

4.13 Pneumatic spray gun -V.A.G 1761/1-

The pneumatic spray gun with original factory optical lens is used
for spraying the seal and bottom protection layer paint.
In addition, all 310 ml adhesive cartridges may be handled by the
spray gun.
AG. Volkswagen AG d
agen
4.14 Pneumatic punchingby and ksw thinning pliers
oes
not
Vol gu
-VAS 1996- d ara
e nte
ris
ho t eo
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
satelettronica
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
4.15 Pneumatic adhesive spray gun -
rrectness of i
V.A.G 2005-
l purpos
♦ Used for the body sealant
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
4.16 Door hinge correction tool
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
18 4. Body repair tools

lkswage es n
o ot g
byV ua
ed ran
General InformationBody
horis Repairs, General Body Repairs - Edition
tee 12.2016
ut or
a ac
ss
4.17 Hose kit 5023 for the inert gas protection
ce
le
un
pt
welding
an
d
itte
y li
erm
ab
♦ Injector hose assembly 5023/1
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness
4.18 Angle grinder -VAS 5174-
o
cial p
f inform
♦ 710 W; diameter 115 mm
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
satelettronica
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
4.19 Angle grinder -VAS 5175-

♦ 1500 W; diameter 180 mm
4.20 Wire brush -VAS 5182-

♦ Use the wire brush to remove the paint in the not easily ac‐
cessible areas (such as the inside of the roof frame).

5 Body bonding yV
olkswage es n
ot g
d b ua
ran
ir se
5.1 Transporter 1991 → utho tee
or
a ac
ss
Handle the bonding points in the following operation steps for re‐
ce
le
pair:
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
satelettronica
om
n
c
i
or
n thi
5.1.1 Separation process:
te
sd
iva
o
pr
cum
r
– Cut the bonding points open using a vibrating cutting knife.

fo
en
ng
t.
yi Co
– Use a knife and a scraper to remove the residual adhesive. t. Cop py
rig
gh ht
yri
5.1.2 Bonding process:
p by
co Vo
by lksw
cted agen
Prote AG.
♦ Material: DCN 180 KD3
– See the instructions for use of the repair adhesive for prepa‐
ration measures of the bonding surface and tips related to
processing.
5.2 Bonding types

In order to improve the stiffness and strength of the body, the
manufacturer uses more and more bonding and spot welding
connections on the body. They are distinguished as follows:
5.2.1 Bonding-strong
Plates are only bonded with adhesive.
Overlap width of the strong bonding surface shall be no less than
2 mm and no more than 4 mm. You must align the bonding surface
if necessary.
Repair measure
– Use the material specified in the repair manual or the acces‐
sory manual to restore the bonding.
20 5. Body bonding
5.2.2 Bonding-spot welding

A conductive adhesive is used between plates for the spot weld‐
ing bonding, and therefore a through welding may be achieved.
Overlap width of the spot welding bonding surface shall be no
more than 1 mm. You must align the bonding surface if necessary.
Welding current is not allowed to be increased for the spot welding
bonding. Due to extrusion of the adhesive, the pre-pressing pe‐
riod must be extended by around 30-50 minutes. The produced
gas must be discharged.
5.3 Repair method for replacing the parts

In addition to spot welding the adhesive, adhesive DA 001 730
A1 and pneumatic spray gun -V.A.G 2005- may be used in com‐
bination.
There are following different operation methods according to the
welding methods (spot welding and plug welding) in case of both
bonding and welding:
satelettronica
5.3.1 Spot welding and bonding
In case of spot welding and bonding for repair, which is like batch
production, renew the areas of all the welding spots and bonding
points.
In case of welding problems, such as three-layer steel plate con‐
nection, only replace the outer plate, and still set the repair AG. Volkswagen A
welding spot on the“old”welding spot. olks
wage
n G do
es n
o
yV t gu
db ara
5.3.2 Plug welding and bonding ho
ris(if spot weld‐
e nte
eo
t
ing is impossible) ss
au ra
c
ce
le
If the spot welding gun fails to reach a certain bonding area, plug
un
pt
an
d
welding may be adopted in this area.

itte
y li
rm
ab
In this case, give up using adhesive in order to ensure the welding
pe
ility
ot
quality. Plug welding spacing is set as 15 mm.

wit
, is n
h re
5.3.3 Welding fume ventilator
hole
spec
es, in part or in w
t to the co
If spot welding is in combination with spot welding adhesive, use

a standard ventilation device, just the same as welding galvanized
steel plates.
rrectness of i
5.3.4 Preparations
l purpos
Before applying adhesive, the sheet metal parts to be welded

must match up.
nform
ercia
There must be neither primer and residual adhesive on the bond‐

m
ing surface in the welding area, nor dirt and grease.

com
tion in
r
In addition, there shall be no more conventional zinc material to

te o
thi
be sprayed in the boding area.

s
iva
do
r
rp
cum
Due to extrusion of the adhesive in case of welding, the welding

fo
en
g
area without paint will come into contact with the adhesive, and
n
t.
yi Co
op
therefore corrosion protection must be ensured. C py
ht. rig
rig ht
py by
5.3.5 Trimming co Vo
by lksw
cted agen
Prote AG.
– Remove the adhesive that flows out.
– Corrosion protection measures ⇒ page 22 .
– Paint the body ⇒ surface technical/chemical material folder.
5. Body bonding 21
6 Corrosion protection measures
6.1 Corrosion protection agen

AG. Volkswagen AG d
oes
olksw not
After the trimming, the material ( cavity corrosion protection wax d by V gu
ara
- DCN 300 KD1 Z2- or inner cavity spray wax - DCN 330 oKD2 ris
e nte
eo
Z1- ) specified by the manufacturer must be used to restore
auth
the ra
adopted ex-factory corrosion protection measure. s s c
ce
e
nl
pt
⇒ See the paint repair manual
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
satelettronica
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
22 6. Corrosion protection measures

7 Waste disposal instructions
7.1 Waste disposal

In order to realize recycling of the repaired or maintained vehicle
parts, Volkswagen and Audi must perform wage
n Aa
G.sorted collection
Volkswagen AG
does of
the produced residual materialsy Vfirst.
olks not
gu b ara
ed
Presort the materials according
ho
ris to the following material groups: nte
e
t or
au ac
– Steel plate or iron material
ss (“scrap steel”) → waste recycler or
metal pulverizing enterprise
ce
e
nl
pt
du
an
itte
– Aluminium →Kassel engine recycling: Waste recycler or pro‐
y li
erm
ab
fessional engine recycler
ility
ot p
wit
– Tyre → partial delivery for retreading
, is n
h re
hole
– Plastic → recycled through local waste processors
spec
es, in part or in w
– Battery → recycled through local waste processors
t to the co
– Waste oil → current waste disposal route
satelettronica
rrectness of i
– Brake fluid → in material recycling preparation process
l purpos
– Anti-freezing fluid → in material recycling preparation process

– Refrigerant → current waste disposal route
nf
ercia
o
– R 12 refrigerant oil → same as engine oil, refrigerant oil R 134a
rm
m
→ in material recycling preparation process
atio
om
n in
c
– For the damping devices such as the bumper shock absorber

or
thi
e
→ drain the oil, and discard it in the usual way

t
sd
iva
o
r
rp
cu
– For inflated shock absorbers, such as air pressure tappet →

o
m
f
exhaust the gas, collect the oil that flows out, and include it
en
ng
t.
yi Co
into the current waste disposal method. t. Cop py
rig
gh ht
– Separate the materials into different categories, in order to yri
p by
o Vo
precisely recycle them according to the categories. For exam‐
by c lksw
cted agen
ple: Remove the tyres from the rims, and dispose them re‐
Prote AG.
spectively.
7. Waste disposal instructions 23

7.2 Air pressure tappet exhaust

– Hold the air pressure tappet by an area x=50 mm in a vice.
WARNING
The vice is only allowed to hold this range, otherwise there will
be a risk of an accident!
– Saw at the first 1/3 point of the whole air pressure tappet cyl‐
inder length (using the end of the plunger lever of the cylinder
as a reference point).
Note
♦ Protective goggles shall be worn during the sawing.

♦ Use a piece of cloth to cover the sawed area, in order to block
the oil that spouts out.
♦ Dispose the oil and the cloth according to current waste dis‐
satelettronica
posal route.
AG. Volkswagen AG d
agen oes
olksw not
V gu
by
7.3 Airbag orised ara
nte
h eo
aut ra
ss c
WARNING
ce
le
un
pt
an
d
itte
y li
There is a risk in case of scrapping the airbags not detonated.
erm
ab
ility
ot p
wit
is n
7.3.1 Waste disposal
h re
ole,
spec
Since December 1, 1997, Volkswagen has been recycling all air‐
t to the co
bags/seat belt tensioners not triggered within the material dis‐
posal range for free. The recycling is carried out by the authorized
sales centre. The blasting components detonated in an accident
rrectne
may be disposed as scrap or industrial waste similar to household
waste.
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
24 7. Waste disposal instructions

8 Contact corrosion protection
8.1 Connection of aluminium alloy/magne‐

sium alloy with steel
Note
♦ In case of connecting aluminium alloy or magnesium alloy with

steel, you must follow the corrosion protection measures de‐
scribed in the following. At the bolt connection points between
aluminium alloy or magnesium alloy and steel:
♦ Fenders
♦ Engine hood
AG. Volkswagen AG d
agen
♦ All doors Volksw
oes
not
by gu
ara
Trunk lid, protective film must be used.
d
♦ orise nte
h eo
ut ra
In casess of screw aluminium alloy or magnesium alloy on steel,
satelettronica
♦ a c
you are only allowed to use a bolt pre-coated with thread lock‐
ce
le
un
ing adhesive, and this bolt may only be used once. Thread pt
an
d
itte
locking adhesives - DCN 154 100 Z1- and -DCN 154 100 Z1- y li
rm
are a chemical protection layer, in order to prevent contact ab

pe
ility
corrosion.
ot
wit
, is n
h re
♦ Electric conduction is not allowed in the non-metal connection
hole
element (door seal and rear trunk lid seal) or the sealing ele‐
spec
ment between two different metals.

es, in part or in w
t to the co
♦ The original accessories dedicated to Lupo 3L start from part

number 6E.
rrectness of i
♦ See corresponding repair manual repair groups for the dedi‐

cated process tips:
l purpos
♦ Lupo 1999 ⇒ Internal body repair

nform
ercia
♦ Lupo 1999 ⇒ External body repair

m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
8. Contact corrosion protection 25

9 Steel plate repair
9.1 High-strength body plate

More and more high-strength steel plates are used in out vehicles.
The range of application for this steel plate is shown in the illus‐
tration repair group 00 in the body repair manual.
What is the high-strength steel plate?
The appearance is similar to common steel plate, but due to the
alloy composition different from the common body steel plate, it
has a higher yield point. This means that the same stress on the
steel plates, the pit on the high-strength steel plate is not as deep
as that on the common body steel plate.
What are the necessary considerations in case of levelling?
Use a common tool to level. Since a bigger projection has a stron‐
ger resilience performance, apply a larger force if necessary.
There may be material breakage in case of material bending de‐
formation.
satelettronica
What are the necessary considerations in case of correction with
a straightener or a hydraulic press?
Since the high-strength steel plate has a larger resilience per‐
formance, a greater stretching must be achieved than the com‐
mon steel plate before restoration to the required position. Due to
a large stress, the common steel plate welded together with the
steel plate will also bear a great load. This increases the stress
on the related parts. In order to prevent the common steel plate
from deformation or cracking, you must use additional fixing
measures.
WARNING
AG. Volkswagen AG d
♦ The overstretched high-strength steel plate will suddenly ksw
agen oes
not
pop up by a length over the expected! y Vol gu
db e
ara
ris nte
♦ For safety, the same as the common body steel ut plate, do
ho eo
ra
not heat the high-strength body steel plate inss acase of re‐ c
storing the deformation.
ce
e
nl
pt
du
an
itte
y li
erm
ab
What are the necessary considerations in case of painting?

ility
ot p
wit
, is n
If the drying radiation heater heats the high-strength steel plate

h re
too fast, the steel plate will deform. If the steel plate is firmly con‐
hole
spec
nected with the reinforcement under it through welding spots or

es, in part or in w
bonding, there will be pits in these positions. These pits may still
t to the co
be seen on the cooled steel plate. For this reason, the radiation
heater is only allowed to slowly rise to the maximum power. It is
safe for drying in a drying room.
rrectness of i
9.2 Galvanized body parts

l purpos
nf
ercia
9.2.1 Preparations
orm
m
atio
m
– The bottom protection layer/sealing material may only be heat‐

o
n in
or c
ed with an electric blower (maximum 420°C) or removed with

thi
e
a wire brush.
t
sd
iva
o
r
rp
cu
– The paint material and the primer material are removed with a
o
m
f
en
ng
paint remover (LLE 812 000 A2) or a plastic brush.

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
26
Prote AG.
9. Steel plate repair
9.2.2 Part cutting

– Try not to use the cutting method (cutting torch) with heating
process (only the rough cutting).
– In order not to damage the zinc layer in the separation area,
the mechanical separation method is preferred, such as: Body
saw.
9.2.3 Connection process

The resistance pressure spot welding (RP) only causes slight
burn to the zinc layer in the spot centre. In addition, the zinc pro‐
tection ring formed around the welding spot provides corrosion
protection.
Whenever possible, always use the resistance pressure spot
welding (RP).
Pay attention to different zinc layer thicknesses (carry out trial
welding) in case of performing resistance pressure spot wwelding
gen AG
. Volkswagen AG
does
s a
(RP). yV
olk not
gu b ara
ed nte
The inert gas protection plug welding (SG) willtho
rinot
s
replace the e or
resistance pressure spot welding (RP) untils the other methods are
au ac
satelettronica
infeasible. s
ce
e
nl
pt
du
Make sure to apply welding primer ( zinc spray - DCN 007 500
an
itte
y li
Z2- ) between the connecting flanges.
erm
ab
ility
ot p
Apply the variable filler (ALN 787 200 10) at the connection.
wit
, is n
h re
9.3 Welding on the galvanized body steel
hole
spec
plate
es, in part or in w
t to the co
WARNING
rrectness of i
Since there is toxic zinc oxide in the welding fume arising from
l purpos
welding of the galvanized steel plates, a good ventilation in the

operation site must be provided, and a proper smoke ventilator
(such as -V.A.G 1586- ) shall be used to discharge the smoke.
nform
mercia
at
om
ion
9.3.1 Inert gas protection plug welding SG of
c
in t
or
his
e
the galvanized steel plate

at
do
priv
cum
or
In order to ensure the repair welding connection quality, you must

f
en
ng
t.
follow the following instructions:
yi Co
Cop py
ht. rig
♦ You must raise the correct intensity (amp) of the spot welding rig ht
py by
transformer.
co Vo
by lksw
cted agen
Prote AG.
♦ In addition, you must readjust the welding wire feeding, as
voltage raising alone only produces a large electric arch (in‐
sufficient melting and porous weld structure).
♦ Use the cylindrical air nozzle to replace the conical air nozzle
(gas blisters after being ejected from the narrow air nozzle).
♦ The welding torch moves from 0° to 10° in the position around
12 mm above the welding body.
♦ Try to use soft welding wires.
♦ Both CO2 and a gas mixture may be used as the protection
gas.
9. Steel plate repair 27

9.3.2 Resistance pressure spot welding RP of

the galvanized steel plate
olkswagen AG
en AG. V
In case of using the resistance pressure spot olkswelding to welding
wag does
not
the galvanized steel plate, you must payed
attention
byV to the following gu
ara
several instructions: horis nte
eo
t
au ra
9.3.3 Welding transformer ss c
ce
le
un
pt
♦ Raise the welding current (amp) by around 10% ,maximum
an
d
itte
y li
30%.
erm
ab
ility
ot p
It is better to extend the welding period on the welding transformer
wit
is n
with the“Welding Period Adjustment”function.
h re
ole,
spec
• The welding period extension value (approximate value) is
according to the thickness of the steel plate:
t to the co
• 0.6 mm -at least 7 periods
rrectne
ss
No spray on the welding spot indicates that the selected welding
o
cial p
satelettronica
period is correct.
inform
mer
9.3.4 Welding clamp
atio
om
n
c
i
♦ Use the hard copper electrode (copper-chromium-zirconium
or
n thi
e
alloy) of a high heat resistance (>400°C).

t
sd
iva
o
pr
c
♦ Often wipe the hard copper electrode, or trim a side contact
um
r
fo
en
ng
surface of a diameter of ∅4 mm.

t.
yi Co
Cop py
♦ Increase the clamping force of the electrode. ht. rig
rig ht
py by
o Vo
9.4 Tearing test
by c lksw
cted agen
Prote AG.
First weld on test plates, and then perform the tearing test, in order
to determine the beat welding result.
Use a force vertical to one steel plate surface to tear a narrow
strip of sample piece from the other steel plate through winding.
At this time, if the welding spot is of a good quality, the sample
piece is not torn on the contact surface, and“Stays There As a
Whole”.
28 9. Steel plate repair

10 Aluminium repair
Note
♦ This instruction only applies to vehicles of a common steel

structure and equipped with aluminium plates on the body.
♦ The range of application for the aluminium plates is shown in
the illustration repair group 00 in the body repair manual.
♦ In addition, the following repair manual also applies to vehicles
olks
wage es n
ot g
(such as Audi A8) of a full-aluminium structure ⇒ body by repair;
V ua
ed ran
Audi vehicle; aluminium; brief instructions or
is tee
th or
au ac
ss
ce
e
nl
WARNING
pt
du
an
itte
y li
erm
ab
Use tools applying to steel material or aluminium material.
ility
ot p
wit
Suggestion: Aluminium tool assembly -V.A.G 2010/2- in the
, is n
h re
tool trolley
hole
spec
satelettronica
es, in part or in w
t to the co
10.1 Painting
The body painting is the same as the steel body.
rrectness of i
It is only allowed to use materials against aluminium corrosion. ⇒
l purpos
Paint repair manual .
nf
ercia
o
WARNING
rm
m
atio
om
Remove adhesive on the ground line after painting.
n in
or c
thi
te
sd
iva
o
r
rp
cu
10.2 Surface treatment
o
m
f
en
ng
t.
yi Co
op
Only use a wire brush made of stainless steel. C py
t. rig
gh ht
yri
Do not use a rough grinding wheel due to lubrication effect.
p by
co Vo
by lksw
cted agen
Use a grinding wheel of a grit size P 80 to P 200.
Prote AG.
You must use cleaning device DA 009 802 in case of using a

grinding wheel, drill bit, milling cutter and disk cutter.
Clean the surface with nitro diluent.
The other surfaces are treated the same as steel.
Note
Cover the aluminium parts in case of grinding and welding the

steel parts. Immediately remove the iron filings dropped on the
aluminium, otherwise contact corrosion may occur.
WARNING
Use tools applying to steel material or aluminium material.

Suggestion: Aluminium tool assembly -V.A.G 2010/2- in the
tool trolley
10. Aluminium repair 29

10.3 Levelling
Aluminium material is easier than steel material to incur material
stretching.
You shall avoid using sharp-edge or hard levelling tools (such as:
Steel hammer), and replace with a plastic hammer, wood hammer
or aluminium hammer.
Direct levelling methods (such as placing an aluminium plate be‐
tween the fixing support and the levelling hammer) shall be re‐
duced.
Levelling of aluminium plates is different from steel plates, and
starts from the projection centre.
Pressing shall be more frequent than knocking for aluminium
plates.
In case of trimming, gently press the bracket. Trimming with an
excessive force may cause material stretching. For this reason,
you shall use hard wood brackets.
However, if the material still incurs stretching, hot air may be used
to perform contraction in order to remove it.
satelettronica
WARNING
The maximum contraction temperature through hot air is 150°

C.
n AG. Volkswagen AG
In case of cracks during levelling, wage
olks you shall replace this part!
does
no
yV t gu
db ara
10.4 Temperature
tho
ris
e
control for heating nte
eo
au ra
Tempering colour may
ss not be identified for aluminium heating. c
ce
le
un
pt
For this reason, you must use a temperature indicating crayon or

an
d
itte
temperature indicating strip to determine the temperature.

y li
erm
ab
ility
The temperature indicating crayon and the temperature indicating

ot p
wit
strip will change their colours when reaching to the specified tem‐
is n
h re
perature
ole,
spec
A - Heating range
t to the co
B - Blank area
C - Temperature indicating crayon or temperature indicating strip
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
30 10. Aluminium repair

11 Plastic repair method
11.1 Material
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
satelettronica
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
WARNING
Pay attention to general accident prevention regulations. It is

not allowed to repair safety related parts of which the functions
(such as collision absorption) may be not guaranteed any more
after repair.
Plastic repair performed using plastic repair kit D 007 700 (con‐
taining plastic part repair adhesive - DCN 180 KU1 Z1- , plastic
part surfactant - DCN 822 150 Z1- , plastic cleaning agent - DCN
195 850 Z2- and mixing nozzle - DCN 001 001- ) may be inter‐
preted as repair of painted body plastic parts, such as bumpers
and rearview mirror covers. Check with care before repair to see
the repair feasibility as well as the economic repair worth (repair/
new part).
11. Plastic repair method 31

You may also repair plastic parts with a texture surface. However,
you may not meet the quality standard of a new part surface.
11.2 Repairing the pit
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
s c
satelettronica
s
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
– First clean and dry the part to be repaired. ht. rig
rig ht
py by
co Vo
– Now use an electric blower to heat the pit area, till the pit may
by lksw
cted agen
Prote
be suitable for being pressed out by using a proper tool.
AG.
– Use a sandpaper of a grit size 120 to grind the pit area.

– Then clean the repair area with plastic cleaning agent - DCN
195 850 Z2- . The ventilation period is 5 minutes.
– Now spray a thin layer of plastic surfactant - DCN 822 150 Z1- ,
and notice that the ventilation period is 10 minutes.
32 11. Plastic repair method

lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
satelettronica
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
op
– Now you may use plastic surfactant - DCN 822 150 Z1- to fill C py
t. rig
the still uneven area, and use a scraper to smooth it.
gh ht
pyri by
Vo
co lksw
by
– An infra-red radiator may be used for accelerated hardening. cted agen
Prote AG.
Place it at 60°C-70°C for 15 minutes.
– Use a sandpaper of a grit size 120 to smooth the repair area.
– Remove the smoothing dust.
– Body painting shall be carried out according to the paint repair
manual.

11.3 Repairing the scratch
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
– First clean and dry the part to be repaired.

mer
atio
m
– You may use a sandpaper of a grit size 80 to remove the raised

o
n
c
material.
i
or
n thi
te
sd
a
iv
o
pr

um
r
fo
en
ng
t.
yi Co
op py
and notice that the ventilation period is 10 minutes. t. C rig
gh ht
yri by
– Now you may use plastic repair adhesive - DCN 180 KU1 Z1-
cop Vo
by lksw
cted
to fill the still uneven area, and use a scraper to smooth it.
agen
Prote AG.
– An infra-red radiator may be used for accelerated hardening.

manual.

11.4 Repair the crack
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos

nform
ercia
– The unevenness caused by stretching may be removed

through the crack drilling (5 mm) and V polishing.
m
a
com
tio
n in
r

te o
thi
s
iva
do
r
rp
cum

fo
en
ng
t.
yi Co
– First you shall use plastic part repair adhesive - DCN 180 KU1 Cop py
. rig
Z1- on the back of the part to be repaired plus reinforced non-
ht ht
rig by
py
woven cloth D 002 KD A1, in order to allow it to overlap the co Vo
by lksw
repair area by at least 20 mm. cted agen
Prote AG.
– An infra-red radiator may be used for accelerated hardening.

– Then you may use plastic repair adhesive - DCN 180 KU1 Z1-
to fill the polished front area, and use a scraper to smooth it.
– You shall also use the infra-red radiator on the front in the
above method for accelerated hardening.


manual.
11.5 Repairing the small hole (the diameter is more than 30 mm)
satelettronica
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform

mer
atio
m
– Use a sandpaper of a grit size 120 in a funnel shape to grind

o
n
c
a 10-20 mm (size a) repair area.

i
or
n thi
te
sd
a
iv
o
pr

um
r
fo
en
ng
t.
– Use a sandpaper of a grit size 120 to burr the area.
yi Co
Cop py
t. rig
gh ht
yri by
cop Vo
by lksw
cted agen
Prote AG.
– First you shall use plastic part repair adhesive - DCN 180 KU1
Z1- on the back of the part to be repaired plus reinforced non-

woven cloth D 002 KD A1, in order to allow it to overlap the

damage area by at least 20 mm.
. Volkswagen AG
a gen AG does
– An infra-red radiator may be used for accelerated
Vol
ksw hardening. not
gu
Place it at 60°C-70°C for 15 minutes. ed by ara
nte
ris
o eo
– Then you may use plastic repair adhesive
aut
h
- DCN 180 KU1 Z1- ra
to fill the polished front area, and use a scraper to smooth it.
ss c
ce
e
nl
pt
– You shall also use the infra-red radiator on the front in the
du
an
itte
above method for accelerated hardening.
y li
erm
ab
ility
– Use a sandpaper of a grit size 120 to smooth the repair area. ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
manual.
rrectness of i
11.6 Plastic repair (glass fibre material)
l purpos
nf
ercia
satelettronica
rm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

WARNING
Pay attention to general accident prevention regulations. It is

not allowed to repair safety related parts of which the functions
(such as collision absorption) may be not guaranteed any more
after repair. AG. Volkswagen A
n G do
wage es n
Volks ot g
by ua
ed ran
1- breakage position oris tee
th or
au ac
♦ Glass fibre pad, polyesterss resin and hardening agent
ce
e
nl
pt
2- surface damage
du
an
itte
y li
♦ Glass fibred-reinforced polyester resin and hardening agent
erm
ab
ility
ot p
wit
, is n
h re
Note
hole
spec
es, in part or in w
Please pay attention to the instructions for use of the manufac‐
t to the co
turer in case of handling material.
rrectness of i
11.7 Repair process
satelettronica
l purpos
11.7.1 Repairing the breakage position
nf
ercia
orm
– Grind around the edge of the breakage position through tilting
m
atio
m
by 45°.
o
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Use a sandpaper of a grit size 150 to grind the surface (shadow

area) about 100 mm around the breakage position, and clean
with plastic cleaning agent - DCN 195 850 Z2- .

– Cut to get three glass fibre pads:-1-overlapping the breakage

position by around 25 mm,-2-overlapping by around 50 mm
and-3-overlapping by around 75 mm.
Note
For a large breakage position, it is suggested to make a holder

with polystyrene foam plastic. Wrap the polystyrene foam plastic
with common PE plastic adhesive tape without printing, in order
to avoid contact with the polyester resin. Then use adhesive tape
to fix the prepared holder inside the breakage position.
Lay the glass fibre
olks
wpads
age es n
ot g
byV ua
– Mix polyester
ris
ed resin (pay attention to the instructions
ran
tee for use of
theuthmanufacturer!)
o
or
a ac
ss
– Apply a thin layer of polyester resin on the breakage/hole.
ce
le
un
pt
an
d
– Use polyester resin to soak the smallest glass fibre pad-1- ,

itte
y li
and lay it in breakage position-4-.
erm
ab
ility
ot p
satelettronica
– The bubbles in polyester resin must be removed immediately
wit
is n
using a sharp tool after the application.

h re
ole,
– Use a sandpaper of a grit size 120 to smooth the applied ma‐ spec
terial after hardening. t to the co
– Clean the repair area with plastic cleaning agent - DCN 195
850 Z2- .
rrectne
– Use the second-2-and third-3-glass fibre pads to repeat the

above operation.
ss o
cial p
f i
11.7.2 Repairing the surface damage

nform
mer
atio
– Polish the damaged surface in a V shape.

om
n
c
i
or
– Use a sandpaper of a grit size 150 to grind the surface (shadow

thi
e
area) about 50 mm around the surface damage position.

t
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Clean the repair area with plastic cleaning agent - DCN 195
850 Z2- .
– Mix glass fibre-reinforced polyester resin (pay attention to the
instructions for use of the manufacturer), and apply it in the
repair area (shadow area).
– Smooth the repair area after hardening, and clean with plastic
cleaning agent - DCN 195 850 Z2- .

12 Glass repair
12.1 Repairing the windshield

In addition to replacement of the windshield, there are other more
economical methods to repair the damaged windshield by a rub‐
ble under some premises. wage
es ks not
Vol gu
Coloured window glass, window glass ed with a colour plate or roof
by ara
nte
glass (Audi A8 and A6) may alsothobe
ris repaired, as their colours eo
come from the coloured middle
s a film.
u ra
c
s
ce
e
Under the following premises, windshield repair is prior to re‐

nl
pt
du
placement.
an
itte
y li
erm
ab
12.1.1 Premises
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
satelettronica
rrectness of i
l purpos
nf
ercia
orm
m
atio
• The damaged area is not directly in the far vision field-1-. This
om
n in
area is a band (A4 size) of an about 29 cm width in the driver’s
or c
direct vision centre in the driving direction, and its upper and thi
te
sd
a
lower edges are restricted by the windshield wiper wiping area.

iv
o
r
rp
cu
o
• The crack -2- extending from the damaged area shall not be
f
en
ng
t.
over 50 mm long and/or extend outward to the marginal area.
yi Co
Cop py
ht. rig
• The diameter of damaged area -1- shall not be over 5 mm. rig ht
py by
co Vo
by lksw
• Middle film -2-or inner layer of glass -3- shall not be damaged. cted agen
Prote AG.
• No dirt or moisture penetrates into the crack area.

• Therefore repair shall not be delayed in case of damage.
If the following damages are not in the far vision field or the edge
area, repair is allowed:
Round hole
40 12. Glass repair

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
Generaloris InformationBody Repairs, General Body
e nte Repairs - Edition 12.2016
h eo
aut ra
c
Combined fracture ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness
Star damage and crack
o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
satelettronica
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
12.1.2 Required special tools, operating equip‐

ment, testing instruments and auxiliary
tools
♦ -VAS 1993- windshield repair kit
Including the following tools:
12. Glass repair 41

1 - Transformer AG. Volkswagen AG d

agen oes
lksw not
2 - Resin scraper (1 set) d byV
o gu
ara
ise nte
r
3 - Mirror ut
ho eo
ra
s a c
4 - Suction hook s
ce
le
un
pt
❑ Use as a vacuum pump
an
d
itte
y li
erm
5 - Tool holder
ab
ility
ot p
6 - Injector
wit
is n
h re
❑ Placed in an opaque
ole,
spec
package after the first
use
t to the co
7 - Resin for at least 15 uses
8 - 12V electric drill
rrectne
9 - Milling cutter and polishing
s
assembly
s o
cial p
f i
10 - Scriber
nform
mer
11 - Ultraviolet lamp
atio
satelettronica
om
n
12 - Film
c
i
or
n thi
te
sd
13 - Battery connection cable
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
12.1.3 Repair description

• Repair is carried out in a place without direct sunlight.
• Temperature at the repair site must be close to room temper‐
ature.
• There shall be no water mist in the operation area.
– Use a hard material scriber to mark the striking area, but do
not extend or remove the glass fragment at the same time.
42 12. Glass repair

– If moisture penetrates, use a suction hook for fixing from inte‐

rior, and use an electric blower for drying. If moisture may not
be removed, stop the repair.
– Place mirror -1-from interior, and adjust it to a position where
you may observe the damaged area well.
– Install tool holder -2-and injector-3- , allowing the rubber seal

of the injector to be accurately placed in the damaged area.
Check with the mirror.
– Completely screw out screw rod-2- from injector -1-.
– Add 2 to 3 drops of resin into injector-1- (resin amount for use
is up to each damaged area).
– The resin bottle shall be immediately inserted into the package
satelettronica
which will be sealed, as resin is sensitive to ultraviolet.
– Wait till resin flows to the rubber seal.
– Screw the screw rod-2- , in order to push and clamp injec‐
tor-1-. If the striking points become clear from the centre, this
indicates a correct pressure.
Note
It is a very slow process for the resin to penetrate into the crack,
and this does not necessarily work right away.
. Volkswagen AG
gen AG does
swa
– In 10 minutes, screw the injector y V to the thread end, in order tot gua
olk no
release pressure. ris
ed b ran
tee
tho or
– Hold the injector to prevent
au it from sliding in case of loosening. ac
ss
ce
le
– Repeat this process (at least 3 times), till all the air in the dam‐
un
pt
aged area is squeezed out. You can see clearly that the crack
an
d
itte
y li
is gone. An 18-bar pressure is produced in case of the injector

erm
ab
pressing.
ility
ot p
wit
is n
– Use the mirror to check in case that the damaged area is fully
h re
ole,
filled. Then end the injection.

spec
– After that, turn the holder and the injector aside and check that
t to the co
if the resin has penetrated into the whole damaged area.
– Once there is still some air inside, place the suction hook in
rrectne
the repair area to exhaust the air.

– Cut cover film -1- and hold it with your hand. Remove the in‐
ss o
jector together with the tool holder, and immediately apply the
cial p
f in
cover film on the damaged area (do not press), in order to

form
mer
prevent air from entering. The film contains an activator for

atio
resin hardening.
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
12. Glass repair 43

– Immediately place the injector back into the package, as resin

is sensitive to ultraviolet, and this allows reuse for the next
repair. Place the released tool holder back into the tool kit, and
remove the mirror and the holder.
– Fix ultraviolet lamp-1- above the damaged area. Use ultravio‐
let to shine the resin for 10 minutes, and then remove the
ultraviolet lamp.
– Use a trimming blade to smooth the damaged area, and polish
it with the 12 V drill and the polishing assembly if necessary.
Note
♦ There is no necessary maintenance period for the repaired

vehicle, and it may be driven immediately.
gen AG
. Volkswagen AG
d a oes
lksw n
♦ For some crack shapes, their
db
y V crack residual traces may not be
o ot g
ua
completely removed, oand
ris this will not impact the repair result.
e ran
tee
th or
♦ After the repair, is restored to the normal bear‐ the
s auwindshield ac
s
ing capacity due to pressed-in and hardened artificial resin,
ce
e
nl
pt
and this avoids continuous expansion of the crack. Hardened
du
an
itte
resin is colourless, and has the same reflective index as glass.
y li
satelettronica
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
44 12. Glass repair

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Service

General InformationBody Repairs,

Service Department. Technical Information

All rights reserved.

Copyright © 2017 Volkswagen AG, Wolfsburg D4B807E3B5B

2.5 Body-cut part and part section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.6 Original connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2.8 Remove the rest part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

6 Corrosion protection measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

10.4 Temperature control for heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

12.1 Repairing the windshield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . tion in

1.1 Part removal

1.2 Battery and welding operation

Before disconnecting the battery grounding, first obtain the code

Switch on the ignition before connecting the battery!

electrical insulation part between the grounding terminal and the ab

welding area. wit

1.3.1 Processing of the electronic control unit

will not be necessary until there is at least one of the following

♦ The housing is significantly deformed or damaged.

♦ The instrument appearance is not damaged, but the bearing

surface or holder is deformed.

♦ The plug connection is damaged or rusted due to moisture.

♦ The functional check or unit self-diagnosis procedure may

as using V.A.G self-diagnosis procedure.

1.4 Paint, glass, soft pad and trim

After refrigerant is added into the air conditioner, its components

are allowed to be neither welded, nor brazed or soldered. If there

and soldering on the vehicle, welding is not allowed either. In term

In case that welding is performed near the refrigerant hose, it is

Invisible ultraviolet will be released during welding, and they may

1.6.1 Remedial measures:

It is suggested to prepare a rinsing bottle for flushing your eyes.

Although refrigerant causes no fire risk, smoking is not allowed in

The temperature of the airbag components must not exceed 100°

C, not even instantaneously.

1.8 Check the seat belts

Systematically check the seat belt system every time after an

If the customer refuses to replace a damaged seat belt, corre‐

1.8.1 Belt body

3-There are burns by cigarettes and the like.

1.8.2 Automatic retractor (locking function)

For safety reason, this driving test shall be performed on a road

1.8.4 Seat belt buckle function

it is not never permissible to use lubricant on the button of the

1.8.5 Seat belt guide member and tongue

– Check the plastic materials for deformation, peeling and crack‐

1.8.6 Fixing piece and fixing point

For damage (such as wear) not caused by a traffic accident, only

♦ The components of the seat belt tensioner are allowed to be

neither opened nor repaired; only new components may be

♦ In case of mechanical damage (buckling deformation and

crack) to the seat belt tensioner, it must be replaced.

en out of the shipping container.

be put back into the shipping container.

♦ Do not randomly place the seat belt tensioner unit.

♦ Do not use grease, cleaning agent or similar media to process

Before cutting off, correcting and/or levelling, you must remove

If the seat belt is completely retracted, in case of an accident, the

During cutting off, correcting and/or levelling, do not pull out

There is no wearing identification device on the vehicle seat belt

1.10.1 The following vehicles have been equip‐ lkswage

Passat 1997 → front and X ab