New Beetle L5-2.5L (BPR) (2007)
Sound Proofing / Insulation: Description and Operation
Body Foam Insulation
The 1998 Beetle has various body cavities that are foam treated.
Foam locations are described in the individual repair instructions.
Foam Insulation is a pre-formed synthetic material that reduces noise transfer to the interior.
The parts catalog shows insulation on illustration 863-20.
The pre-formed foam parts are installed during body assembly, they expand during drying time in the paint shop oven at approx.180° C (388° F)
after priming.
As these temperatures cannot be achieved under normal workshop conditions, proceed as follows:
Prerequisites
‹› Before continuing with this procedure, ensure the replacement part is correctly prepared.
‹› Remove excess foam material.
‹› Repaint, apply two coats (wet on wet) of glass/paint primer D009 200 02 if necessary, flash-off time - approx.10 min.
Replacing insulation
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Apply sealing cord AKD 497 010 04 R10 around circumference of insulation.
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Install insulation.
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Attach new part (e.g. A pillar) and position new part by pressing gently in insulation area and weld in place.
‹› Do not SG weld 15 mm (0.59 in.) either side of insulation.
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Re-under coat repaired area after painting vehicle, as required.