Replacing

Replacing

Removing

• Due to the different types of steel and material strength, use only welding equipment approved by Volkswagen to perform any service work.

• For a list of welding equipment and body tools approved by Volkswagen, refer to ServiceNet.






- Cut off the crash tube on the ends - 1 -.

- Remove the original joint from the double floor panel and the tunnel reinforcement.






- Remove residual material.

- Completely remove adhesive remains and grind bonding surfaces down to bare metal.

- Apply corrosion protection to the adhesive surfaces, which will not be welded.

- Lightly sand the adhesive surfaces in the connection.

Installing

• Use only welding equipment approved by Volkswagen. Refer to ServiceNet.

Preparing New Parts

New Part

• Crash Tube

• Tunnel reinforcement

• Double Floor Panel

• 2K body adhesive (D 180 KD3 A2)

- Weld the double floor panel - 1 - to the tunnel reinforcement - 2 - with a straight-line spot weld seam.






- Drill holes with a 8 mm diameter for a gas shielded arc plug weld seam.

Welding

• New part must be installed within 90 minutes, otherwise bonding properties of adhesive will be impaired.






- Apply 2K body adhesive (D 180 KD3 A2) in the areas where it was bonded during production.

- Fit new part to vehicle standing on alignment bracket set and secure.

- Check fit with attachments.






- Weld the double floor panel to the tunnel reinforcement with a gas-shielded arc continuous weld seam (staggered) and gas-shielded arc plug weld seam.

- Center the crash tube - 1 - and then weld it with a gas-shielded arc continuous weld seam (staggered).

- Install the B-pillar reinforcement.

- Install side member.

- Install side panel.