Sedan

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.
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:

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
- Apply sealing cord AKD 497 010 04 R10 around circumference of insulation.
- Install insulation.
- Attach new part (e.g. A pillar) and position new part by pressing gently in insulation area and weld in place.

NOTE: Do not SG weld 15 mm (0.59 in.) either side of insulation.

- Re-under coat repaired area after painting vehicle, as required.