Many times during the course of a repair, fit and finish of a particular part is critical to the final outcome. A new part that has been replaced or removed for repair may just not look the same as when it was originally installed on the vehicle. Manufacturers often publish a procedure to correct, modify or update various repair techniques or replacement parts. You may never be aware of the problem until a customer points out the defect or you complete the repair.

This article describes the repair procedure to correct a wavy rear bumper on certain 2005 to 2007 Volkswagen New Beetles and New Beetle convertibles.

Condition
Bumper Rear Cover, Deformation, U.S.
Customer may complain about wave or distortion in bumper rear cover.

Technical Background
Incorrect assembly of the reinforcement (part # 1Y0813389) due to weld splatter located on the studs of the rear bumper.

Service Procedure
Always refer to ALLDATA for safety procedures, identification of material types and welding procedures.

Step 1
• Disassemble rear bumper module (bumper cover
  and rear mud-wings).
Step 2
• Disassemble reinforcement.
Step 3
• With the help of a chisel, remove the weld pieces (seen at right) adhered to the bolts to ensure a correct assembly of the reinforcement to the rear apron.
Step 4
• Assemble reinforcement.
Step 5
• Assemble rear bumper module starting from call-out #1 to call-out #10 (from center to both sides of the bumper cover) as shown in the illustration below.
Step 6
• Tighten the rest of the screws of the rear bumper module in proper sequence.

Writer Dan Espersen is the ALLDATA CollisionConnectSM Program Manager. Espersen is I-CAR Platinum Certified, a Gold Pin Member of the Collision Industry Conference (CIC) and holds an AA Degree in Automotive Technology. He has 15 years of experience in the collision industry and 17 years of experience in the automotive industry.

© 2007 ALLDATA LLC. All rights reserved. All technical information, images and specifications are from the ALLDATA Product. ALLDATA is a registered trademark of ALLDATA LLC. All other marks are the property of their respective holders. Volkswagen, New Beetle and New Beetle Convertible are registered trademarks of the Volkswagen of America Motor Company and are being used solely for reference and application purposes.