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Edition 02.03
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Paint, windows, upholstery, trims
It is prohibited to park other vehicles without protection in the premises used to repair the bodies (risk of fire resulting from flying sparks, battery destruction, deterioration of the paint andwindows).
Welding work
Warning! As toxic zinc oxide is contained in the fumes pro- duced during steel sheet welding suitable exhaust
systems, e.g. V.A.G 1586 must be provided to prop-erly ventilate the workshop and evacuate the gases.
Before starting welding operations on the vehi- cle, protect the rest of the vehicle by placing fire-
proof blankets or matting around the work area. If this measure is thoroughly implemented, it will
not be necessary to remove all the interior vehi-
cle equipment. However, for safety reasons a fire extinguisher must always be within reach during welding operations. If the mechanic per- forming the welding operation is unable to su-
pervise the inside of the vehicle, a second per- son must be called upon. The gases during welding are toxic and must be exhausted. Notes: Remove battery before all welding opera- tions.
Disconnect AC generator and ignition trans- former
Disconnect the earth connections of the electrical control units
page 00-5.
Air conditioning
It is prohibited to weld or hard or soft solder on parts of the filler air conditioning. This also ap- plies for welding and soldering operations on the vehicle if there is any risk that parts of the air conditioning heat up. During paint repairs the temperature of the objects placed in the drying oven or in its pre-heating zone must not exceed
80 °C because heating causes a strong over-pressure that may result in the system explod- ing.
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Edition 02.03
S00.5119.56.20Tools
Tools required
Right angle grinder (e.g. EBU 18-E2)
One-hand right angle grinder (e.g. WS-125) and wire brush
Welding point loosening tool (e.g. Variodrill
V.A.G 1731)
Sheet metal and body saw (e.g. V.A.G 1523)
Welding fume extraction (e.g. V.A.G 1586 A)
Body tool carrier (e.g. V.A.G 1439)
Door tension adjuster (e.g. V.A.G 1438)
Underbody sealant gun (e.g. V.A.G 1379)
Burring pliers
- To burr panels e.g. for overlapping seams
Punch pliers (e.g. V.A.G 1329)
- To punch holes in panels (e.g. for shielded arc plug weld)
Panel nibbler
- To cut out panels without warpage or burr- ing (e.g. when subsequently fitting a glasssun roof)
Pneumatic gun (e.g. V.A.G 1761/1)
- Pneumatic gun to produce seals and apply underbody protection having the same ap- pearance as the original factory finish.
- Moreover all 310 ml cartridges can be used in this gun
Pneumatic gun for 2k window glue (e.g. VAS 5237)
Pressure beaker gun for hollow space seal-
ing (e.g. V.A.G 1538)
Inert gas shielded welding tool
Spot welding and sheet panel machining tool
(e.g. V.A.G 1713)
Rig alignment bench Celette M85 with align-
ing device and straightening angle set VAS 5020/1
Basic equipment (e.g. V.A.G 1366/3)
Rod grinder with wire brush
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