Procedures

Body Foam Insulation

The 1999 Jetta has various body cavities that are foam treated.
Foam treated locations are described in individual repair instructions.
Foam treating reduces noise transfer to the interior.
Foam insulation is a pre-formed synthetic material.
The parts catalog shows insulation.
The pre-formed foam parts are installed during body assembly, they expand during drying time in the paint shop oven at approx.180 degrees C (388 degrees F) after priming.
As these temperatures cannot be achieved under normal workshop conditions, proceed as follows:

Requirements
Before continuing with this procedure, ensure that the part for replacement is correctly prepared.
- Remove excess foam material.
- Repaint, apply two coats (wet on wet) glass/paint primer D009 200 02 if necessary, flash-off time - approx.10 min.

Replacing insulation
- Apply sealing cord AKD 497 010 04 R10 around circumference of insulation.
- Install insulation on vehicle.
- Attach new part (e.g. A-pillar) and locate new part by pressing gently in area of insulation and weld in place.
- Do not SG weld 15 mm (0.59 in.) either side of insulation.
Re-under coat repaired area after painting vehicle, as required.