Engine Bulkhead - Bulkhead Sealing During PDI
Group: 51Number: 93-02
Date: November 15, 1993
Subject:
Supplementary Sealing Procedure for Engine Bulkhead - Required at P.D.I.
Models:
Golf III/Jetta III 1994 M.Y. (Up to VIN 036254)
VWUS Service has identified a source of potential water leaks which affects early 1994 Golf III and Jetta III vehicles. The leakage occurs through gaps in the sealant where the removable bulkhead cross panel is bolted to the engine bulkhead flange, an integral part of the vehicle. Water ingress will typically occur while driving the vehicle in the rain, not while parked. Water from the A/C evaporator drain can also re-enter the vehicle through these gaps in some instances.
Because leak testing in this area can be time consuming and requires partial disassembly of the interior, it has been determined that a supplementary sealing procedure will be performed on all 1994 vehicles that have not been checked and corrected at our Post Production Centers. These vehicles will be identified with a yellow sticker on the bulkhead panel.
Perform the following procedure on all 1994 Golf III and Jetta III vehicles prior to retail delivery, except:
1. Do not perform the procedure if the VIN is 036254 or greater.
2. Do not perform the procedure if the vehicle has a yellow sticker affixed to the bulkhead panel directly below the A/C expansion valve (or in the same area on non-A/C vehicles).
Read all instructions before starting this procedure.
Required Materials:
Note:
All materials are available through Kent Industries. Phone 1-800-654-6333 for order placement or customer service. Approximately 4 vehicles can be completed with each 16 oz. can of liquid rubber, but the actual quantities of each sealant required may vary from vehicle to vehicle. The applicator pump and extension tubes can be used indefinitely if kept clean.
Procedure (hoist is not required):
Open hood. Locate aluminized heat shield on engine bulkhead, directly behind the exhaust: system down pipe.
Fold lower half of this heat shield upward against the upper half to expose the bulkhead seam which requires re-sealing (indicated by bold line between arrows "A" and "D" in illustration). The fold in the heat shield should occur directly below the brake lines which run horizontally across the bulkhead panel.
Clean/prepare the seam area surface with acrysol solvent spray.
Thread one extension tube onto the applicator pump nozzle and install the pump assembly onto a 16 oz. can of the liquid rubber material.
Apply a 1/4" bead of liquid rubber sealant into the flange seam gap for the entire length of the lower bulkhead seam between arrows "A" and "C" in the illustration. Keep in mind that the sealants in use here are "flowable". They will seek out and fill any gaps, so they will not maintain the appearance of a 1/4" bead after application. Pay particular attention to the lying areas of the seam indicated by arrows "B" and "C", especially underneath the brake booster and behind the steering boot.
After application, use the acrysol solvent to clean up any excess material. Also, wetting your fingertip with the acrysol will allow you to smooth and pack the tacky liquid rubber into the seam if necessary, with no effect on the curing process and no transfer of material to your fingertip.
If desired, a compatible spray-on leak sealer is also available which can be used as a quickly applied second coat over hard to reach areas. Care must be exercised when applying this product as it applies like paint and flows very freely. By keeping the extension tip very close to the surface and using minimal pressure on the spray tip, control of the application can be maintained.
Allow at least 1/2 hour for the material to cure to the touch, and then fold the aluminized heat shield back down into place. Make sure the heat shield does not interfere with the functioning of the evaporator drain on A/C equipped vehicles.
Labor Operation: 5165 51 0
Time Allowance: 50 T.U.
Material Allowance: $3.00 per vehicle