Volkswagen Golf / Golf Plus. Manual - part 234

 

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Volkswagen Golf / Golf Plus. Manual - part 234

 

 

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1.7.2

Installing

Caution

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

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

be damaged.

– Carefully fit door outer panel.
– Insert all bolts -2, 3 and 4-.
• Observe correct usage for the different types of bolts.
♦ Feature for bolt -2-: bolt with pointed end and thin washer.
♦ Feature for bolt -3-: bolt without pointed end but with thick

washer.

♦ Feature for bolt -4-: bolt with pointed end and thick washer.
– Check whether the securing strut guide pins are located in the

appropriate guide holes in door inner part. Then first tighten

all bolts -2, 3 and 4-.

General body repairs, exterior - Edition 04.2008

1. Front door    

57

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• Observe correct specified torque for the different types of

bolts.

Specified torque for bolt -2-: 10 Nm.
Specified torque for bolt -3-: 14 Nm.
Specified torque for bolt -4-: 10 Nm.
Further installation is performed in the reverse order of removal.

1.8

Installing new outer panel for door

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.

Note

Observe section, installation notes for bonding-in a new door out‐

er panel 

⇒ page 63

General body repairs, exterior - Edition 04.2008

58

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

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• The old (damaged) door outer panel with retaining rails is re‐

moved 

⇒ page 55

– Install front -2- and rear -6- retaining rails to door inner part.

For this use “bolt without point with thick washer”.

Specified torque for bolts -3- and -5-: 10 Nm.
– Fit two guide bolts in lower edge of door inner part.

The painted door outer panel is first offered up without bonding

agent.
Assembly block from assembly tool set -T 10237- is required to

offer up the door outer panel. A strip of “Tesa Power Strips large”

-6- is applied on the lower side. The pin has the minimum dimen‐

sion for the gap width. The non bonded surface is brought into

position with the adjacent component.
– Bond assembly block -3- on door outer panel.
– Guide door outer panel -1- over guide bolts in lower edge of

door inner part.

– Adjust gap to side member and door outer panel height using

wedges -4- from assembly tool set -T 10237- .

General body repairs, exterior - Edition 04.2008

1. Front door    

59

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– Place door outer panel with assembly blocks on surrounding

components -2 and 5-.

– Check gap dimension using setting gauge -3371- ⇒ Body Re‐

pairs; Rep. Gr.  00 ; Technical data; Body gap dimensions .

– If gap dimension cannot be adjusted further, door inner part

must be adjusted 

⇒ page 52

– Remove door outer panel again.

– Apply a bead of adhesive material -2- using cartridge gun -

V.A.G 1628- to front -1- and rear -3- retaining rails.

General body repairs, exterior - Edition 04.2008

60

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

 

 

 

 

 

 

 

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