Volkswagen Golf / Golf Plus. Manual - part 231

 

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Volkswagen Golf / Golf Plus. Manual - part 231

 

 

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57 – Front doors, door components, central locking

1

Front door

1.1

Tools

Special tools and workshop

equipment required
♦ Socket -T 10072-
♦ Assembly tool -T 10118-
♦ Door alignment tool -3320-
♦ Universal joint for 3320

-3320/1-

♦ Bit for 3320 -3320/2-
♦ Bit for 3320 -3320/3-
♦ Roller for fitting door insu‐

lation foil -3356-

♦ Torque wrench 5...50 Nm -

V.A.G 1331-

♦ Setting gauge -3371-

General body repairs, exterior - Edition 04.2008

1. Front door    

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♦ Cartridge gun -V.A.G 1628-
♦ Cartridge heater -V.A.G

1939 A-

♦ Wedge -3409-
♦ Assembly tool set -T

10237-

1.2

Materials

♦ 1K window adhesive

DH 009 100 01

2)

 

3)

♦ Glass primer/paint primer D 009 200 02

1)

♦ Cleaning solution

D 009 401 04

1)

♦ Primer applicator

D 009 500 25

1)

♦ Door repair kit

D 438 520 A2

4)

1)  Materials are stored in box D 004 700.

2)  Observe minimum curing period 

⇒ page 64

 .

3)  Heat, according to manufacturers instructions, using cartridge heater -V.A.G

1939- .
4) Folding cardboard carton with 10 sheets each with 15 adhesive strips.

1.3

Assembly overview - door assembly

A new door concept has been introduced with Golf 2004.
The door consists of a door inner part -6- and door outer panel

-1-.

General body repairs, exterior - Edition 04.2008

46

     Rep. Gr.57 - Front doors, door components, central locking

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The parts are joined by the front -7- and rear -5- retaining rails.
The retaining rails are bolted to the door inner part and bonded

to the door outer panel.
The door inner part -6- serves amongst other things as the pre‐

viously known assembly carrier. Loudspeaker, window regulator,

window regulator motor, wiring, window guides, exterior mirror

and door lock are mounted on the door inner part.
The door outer panel -1- is additionally bolted to the lower edge

of the door inner part. The window slot seals, insulation and door

outer handle are mounted on the door outer panel.

Caution

Bolts of different types are used to secure door outer panel. If

these are fitted in the wrong positions, the door outer skin will

be damaged.

1 - Door outer panel

❑ Removing and installing

⇒ page 94

2 - Edge protection

❑ Between door outer skin

and door inner panel

3 - Bolt

❑ Feature: bolt with poin‐

ted end and thin washer.

❑ Qty. 6 on lower edge
❑ Qty. 2 in area of top sec‐

tion of trim

❑ 10 Nm

4 - Rear retaining rail

❑ Adhesive:

DH 009 100 03

5 - Bolt

❑ Feature: bolt without

pointed end but with

thick washer.

❑ Qty. 10 for both retain‐

ing rails on 4 door mod‐

els

❑ Qty. 11 for both retain‐

ing rails on 2 door mod‐

els

❑ 14 Nm

6 - Door inner part

❑ Assembly overview

⇒ page 65

7 - Front retaining rail

❑ Adhesive:

DH 009 100 03

8 - Bolt

❑ Feature: bolt with pointed end and thick washer.
❑ Qty. 1 for front area of top section of trim

General body repairs, exterior - Edition 04.2008

1. Front door    

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❑ 10 Nm

9 - Insulation

❑ Self-adhesive
❑ To bond, first heat the insulation and then press on firmly

10 - Clip

❑ Qty. 6

11 - Window slot seal

❑ Must be fitted before assembling door outer panel.

1.4

Assembly overview - door hinges

Caution

Bolt of eccentric pin -10- should not be loosened under any

circumstances on vehicles up to 01.2004. It cannot be tight‐

ened again using normal workshop tools.

General body repairs, exterior - Edition 04.2008

48

     Rep. Gr.57 - Front doors, door components, central locking

 

 

 

 

 

 

 

Content   ..  229  230  231  232   ..