Volkswagen Golf / Golf Plus. Manual - part 235

 

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Volkswagen Golf / Golf Plus. Manual - part 235

 

 

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Use fixing block from assembly tool set T10237 to insert door

outer panel. Two strips of “Tesa Power Strips large” -5- are bon‐

ded to the contact surfaces.
– Guide door outer panel -1- over guide bolts in lower edge of

door inner part.

– Bring door outer panel with assembly blocks -3- into contact

with surrounding components.

– Adjust the gap to side member and adjust door outer panel

height using wedges -4- from assembly tool set.

– Check gap dimensions using setting gauge -3371- ⇒ Body

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

– Bond short fixing block -2- evenly on the replacement door and

the adjacent components.

Note

A curing period of 180 minutes must be observed before per‐

forming further work on the door which has been bonded.

– Further installation is performed in the reverse order of re‐

moval 

⇒ page 57

 .

General body repairs, exterior - Edition 04.2008

1. Front door    

61

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1.9

Removing and installing retaining rail on

door outer panel

1.9.1

Removing retaining rail

Caution

The following work steps are to be carried out with great care.

As door outer skin is to be reused, dents and scratches must

be avoided.
When cutting through the adhesive bead, always hold the re‐

taining rail and door outer skin together as shown in the illus‐

tration. If this is not done, the door outer skin will come away

from the retaining rail, thus rendering it useless.

Note

The following work steps should be carried out with the aid of an

assistant.

Door outer panel with retaining rail is removed 

⇒ page 55

– Place door outer panel -1- on firm surface and protect door

outer panel against scratches.

– Fit reel device -2- in place.
– Secure cord -5- on reel device and counterhold -4-.
– Hold retaining rail and outer skin together securely when cut‐

ting through adhesive bead.

– Cut through adhesive bead of retaining rail -3- and door outer

panel -1- with cord up to just over half way.

General body repairs, exterior - Edition 04.2008

62

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

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– Once adhesive bead has been cut through to just over half

way in step one, turn reel device -2- around and insert cord

-5- in side still bonded.

– Hold retaining rail -3- and outer skin -1- together securely

when cutting through adhesive bead further.

– Cut through second half of adhesive bead.

1.9.2

Installing retaining rail

– Cut away remainder of adhesive bead to a minimum on outer

panel with the greatest of care, ensuring that no damage is

caused to the paintwork.

– Remainder of work procedure is described in chapter entitled

“Installing new door outer panel” 

⇒ page 58

Note

Observe also “instructions for bonding in new door outer panel”

when installing a new retaining rail.

– In place of removed retaining rail, install a new retaining rail

on the door inner panel.

– Apply adhesive to new retaining rail.
– Tighten screws to secure door panel on lower edge and on

retaining rail still in place.

– Secure door outer panel on new retaining rail with fixing

blocks.

1.10

Installation instructions for bonding in

new door outer panel

Note

If both door outer panels on one side have to be renewed, the

sequence must be observed. The rear door outer panel is

aligned and bonded in first, followed immediately by the front

door outer panel. The long fixing blocks must be bonded in

from the rear door outer panel to the front door outer panel.

If door outer panel CDP coating is damaged on inside in bond‐

ing area, or if this area has been painted, this area must be

primed with glass/paint primer D 009 200 02.

The 1K window adhesive DH 009 100 must be heated in car‐

tridge heater -V.A.G 1939 A- for 20 minutes.

General body repairs, exterior - Edition 04.2008

1. Front door    

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– Clean contact surfaces on retaining rails thoroughly using

cleaning solution D 009 401 04.

– Apply adhesive material to appropriate surfaces at right angles

to retaining rail using cartridge gun -V.A.G 1628- .

WARNING

Door outer panel must be installed within 10 minutes, or ad‐

hesive properties of adhesive will be impaired.

♦ With assistance of both assembly blocks, place door outer

panel on retaining rails, align with wedges and setting gauge

-3371- and press contact surfaces of assembly blocks onto

surrounding components.

♦ Secure door with fixing blocks during curing time.
♦ After installation door outer panel must align with other com‐

ponents and gap dimension must be even.

♦ If adhesive bead is too thick and adhesive exudes between

retaining rail and door outer panel, excess adhesive must be

removed.

1.11

Minimum curing period

WARNING

Special standards must be adhered to when replacing bonded

door outer panels. One of these standards is, for example, that

a freshly bonded door outer panel must comply with the safety

requirements,  even  in  an  accident,  following  the  minimum

specified curing period.

For 1-pack adhesive DH 009 100, the minimum curing time for

the door outer panel is 180 minutes.
Minimum curing time means the time from bonding-in the door

outer panel to the time the vehicle is brought into use or further

work is carried out. During this time, the vehicle must stand on a

level surface at room temperature (at least 15  C).

WARNING

Vehicle is safe to use only after the minimum curing period is

completed.

1.12

Cleaning off excess adhesive sealing

material

– It is recommended to use cleaning solution D 002 000 10 as

a cleaner. Observe the appropriate safety precautions when

performing this work.

Caution

When cleaning vehicle, the door outer panel just bonded-in

must not be moved.

General body repairs, exterior - Edition 04.2008

64

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

 

 

 

 

 

 

 

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