Volkswagen Golf / Golf Plus. Manual - part 241

 

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Volkswagen Golf / Golf Plus. Manual - part 241

 

 

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58 – Rear doors, door components

1

Rear 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. Rear 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

6)

 

7)

♦ Glass primer/paint primer

D 009 200 02

5)

♦ Cleaning solution

D 009 401 04

5)

♦ Primer applicator

D 009 500 25

5)

♦ Door repair kit

D 438 520 A2

8)

5)  Materials are stored in box D 004 700.

6)  Observe minimum curing period 

⇒ page 103

 .

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

1939- .
8) 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

86

     Rep. Gr.58 - Rear doors, door components

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The parts are joined by the front -7- and rear -4- retaining rails.
The retaining rails are bolted to the door inner part and bonded

to the door outer panel.
Loudspeaker, window regulator, window regulator motor, wiring,

window guide 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.

1 - Door outer panel

❑ Removing and installing

door outer panel

⇒ 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. 4 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. 11 on both retaining

rails

❑ 14 Nm

6 - Door inner part

❑ Assembly overview

⇒ page 104

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
❑ 10 Nm

9 - Insulation

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

10 - Clip

❑ Qty. 5

11 - Window slot seal

❑ Must be fitted before assembling door outer panel

General body repairs, exterior - Edition 04.2008

1. Rear door    

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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.

Note

The right side is shown. The left side is similar.

The hinge bolts must always be renewed if loosened.

Hinges are now one piece.

The specified torque for the hinge bolts to the door (bolts -4, 6 and 14-) has been revised.

1 - Door

❑ Removing and installing

⇒ page 89

❑ Adjusting 

⇒ page 91

2 - Guide bolt

❑ 10 Nm

3 - Door hinge with arrester
4 - Multi-point socket head bolt

❑ 50 Nm
❑ Bolts must always be re‐

placed by new ones af‐

ter being undone

5 - Multi-point socket head bolt

❑ Installed from inside the

vehicle

❑ Remove B-pillar lower

trim ⇒  General body re‐

pairs, interior; Rep. Gr. 

70 ; Trim/insulation; Pil‐

lar and side panel trim

❑ 20 Nm + 

1

/4 turn further

(90°).

❑ Bolts must always be re‐

newed after being loos‐

ened

6 - Multi-point socket head bolt

❑ 50 Nm
❑ Bolts must always be re‐

newed after being loos‐

ened

7 - Multi-point socket head bolt

❑ 20 Nm + 

1

/4 turn further

(90°).

❑ Bolts must always be replaced by new ones after being undone

General body repairs, exterior - Edition 04.2008

88

     Rep. Gr.58 - Rear doors, door components

 

 

 

 

 

 

 

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