51 31... Notes for bonding sound insulation (SI), doors

Work steps for removing and installing sound insulation 

• Click on "underlined cross-reference" to display at the end of this document

General 

Sound insulation is bonded to the inner door panel.

Bonded sound insulation must not be subjected to load (e.g. leak test) before 5 hours have elapsed.

On-the-job safety 

When working with bonding products (adhesive, cleaning agent, etc.):

• Wear safety goggles, protective gloves and if necessary an apron.
• Ensure rooms are well ventilated.
• Change work clothing contaminated with adhesive immediately.
• Change work clothing contaminated with solvents and swelling agents immediately (keep spare work clothing on hand).
• Take skin protection measures, provide washing facilities including hot water, use silicone-free skin creams
• Provide eye douche facilities, change water regularly (once a month).
• Comply with the relevant safety regulations

Handling adhesive area on inner door panel 

Adhesive

1. Butyl bead applied to sound insulation with protective film
2. Butyl mini-round profile 1□ 3 mm from the roller
3. Butyl round profile □ 6 mm from the roller

Cleaning

1. Isohexane (benzine)
2. 2-propanol (isopropanol)

   Under no circumstances: paint thinning 

3. Carry out bonding only after an air drying time ≥ 1 min. Air drying time may be omitted if the entire bonding surface is wiped with a dry cloth
4. After cleaning, the bonding surface may not be touched with hands or fouled again

Repair in area of sound insulation, door 

Repair

in the event of damaged sound insulation or leakage

• Cut the butyl rope between the sound insulation and the inner door panel with a sharp knife
• After the repair is finished, position a new butyl rope □ 3 mm directly on the original adhesive bead
• Heat the butyl bead with a standard hot air blower until the butyl rope strings when touched slightly. Do not damage the sound insulation in the process
• Press down with special tool 51 0 300 . Perform this work extremely carefully because the increased amount of adhesive requires pressure of ≥ 20 N/cm² (compared to firm thumb pressure ~ 30 N/cm² )
• Visually check the adhesive bead and its compression (no capillaries or broken adhesive bead permitted)
• In the cases mentioned, the complete sound insulation must be replaced. After removing the sound insulation, removal all butyl remnants from the inner door panel. Apply 6 mm □ butyl rope to new sound insulation
• Press down with special tool 51 0 300 to ≥ 20 N/cm² (compare to firm thumb pressure ~ 30 N/cm² )

The sound insulation must be bonded watertight below the door lock 

• Flat bonding surface required all round
• No bonding in event of moisture (e.g. condensation, etc.)
• Bonding area must not show any traces of adhesion-reducing residues (e.g. separating agents, greases, oils, paraffins, plastisols, cavity wax, polishing dust residues, etc.)
• Remove the protective film directly before joining (under no circumstances remove earlier, since the butyl, because of its stickiness, will very quickly pick up adhesion-reducing dirt contaminants)
• The sound insulation must be attached with positional accuracy to the inner door panel, because it is no longer possible to change the position without damaging the butyl bead
• With repainted areas, the maximum permitted temperature of 90°C may not be exceeded in the area of the sound insulation. Otherwise, the sound insulation must be removed (and replaced, if necessary).

Expiration date of adhesive 

24 months, see label on packaging

Disposal of the cleaning cloth 

Cleaning cloths and cleaning agent residues are hazardous waste (see also safety data sheet)

Disposal of adhesive 

Hazardous waste (see also safety data sheet)

Work steps for removing and installing sound insulation 

See repair instructions  See 5148060 REMOVING AND INSTALLING/REPLACING SOUND INSULATION IN LEFT OR RIGHT FRONT DOOR  or 5148070 REMOVING AND INSTALLING/REPLACING SOUND INSULATION ON LEFT OR RIGHT REAR DOOR .