Volkswagen Golf / Golf Plus. Manual - part 244

 

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Volkswagen Golf / Golf Plus. Manual - part 244

 

 

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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 102

General body repairs, exterior - Edition 04.2008

1. Rear door    

97

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

moved 

⇒ page 94

– 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.
To fit door outer panel, assembly block from assembly tool set -

T 10237- is required. A strip of “Tesa Power Strips large” -6- is

applied on the lower side. The pin has the minimum dimension

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

98

     Rep. Gr.58 - Rear doors, door components

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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, door inner part must be

adjusted 

⇒ page 104

– 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

1. Rear door    

99

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To fit door outer panel, assembly block from assembly tool set -

T 10237- is required. Two strips of “Tesa Power Strips large” -5-

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

door inner part.

– Place door outer panel with assembly blocks -3- on surround‐

ing components.

– Adjust gap to side member and 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 96

 .

General body repairs, exterior - Edition 04.2008

100

     Rep. Gr.58 - Rear doors, door components

 

 

 

 

 

 

 

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