Volkswagen Golf Variant / Jetta. Manual - part 20

 

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Volkswagen Golf Variant / Jetta. Manual - part 20

 

 

– Fit two guide bolts -4- in lower edge of door inner part -1-.

The painted outer panel for the door is first offered up without

bonding agent.
Assembly blocks -3- from assembly tool set -T10237- are required

when fitting outer panel on door. A strip of double-sided adhesive

tape -6- is applied on the side with a cut-out step. The pin has the

minimum dimension for the gap width. The surface with no ad‐

hesive tape is brought into position on the adjacent panel.
– Stick the assembly block -3- on outer panel -1- of the door.
– Guide outer panel -1- over guide bolts on lower edge of door

inner part.

– Adjust gap to sill and height of outer panel on door using

wedges -4- from assembly tool set -T10237- .

– Lay door outer panel -1- with assembly blocks on adjacent

panels -2- and -5-.

1. Front door    

77

 

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

be adjusted 

⇒ page 70

– 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.

Note

Adhesive -DA 004 600 A2- can be used for this procedure and is applied with double cartridge gun -VAS 5237- .

There is no requirement to preheat.

78

 

hesive tape -5- are applied on the contact surface.
– Guide outer panel -1- over guide bolts on lower edge of door

inner part.

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

surrounding components.

– Adjust gap to sill and height of outer panel on door using

wedges -4- from assembly tool set.

– Check gap/shut line using setting gauge -3371- ⇒ Body Re‐

pairs; Rep. Gr.  00 ; Body dimensions .

– Bond short fixing blocks -2- evenly on the replacement door

and the adjacent components.

Note

A waiting period of 90 or 180 minutes must be observed before performing further work on the bonded door

⇒ page 82

 .

– Further installation is performed in reverse order of removal

⇒ page 75

 .

1. Front door    

79

 

door outer panel

1.9.1

Removing retaining rail

Caution

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

As outer panel is to be reused, dents and scratches must be

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

taining rail and outer panel together as shown in the illustration.

If this is not done, the outer panel will come away from the

retaining rail, thus rendering it useless.

Note

The following procedures should be carried out with the aid of an

assistant.

80

 

 

 

 

 

 

 

 

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