Volkswagen Golf Variant / Jetta. Manual - part 21

 

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Volkswagen Golf Variant / Jetta. Manual - part 21

 

 

 .

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

outer panel against scratches.

– Secure reel -2- on outer panel of door -1-.
– Secure cord -5- on reel -2- and counterhold -4-.
– Hold retaining rail and outer panel of door together securely

when cutting through adhesive bead.

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

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

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

way in step one, turn reel -2- around and insert cord -5- in side

still bonded.

– Hold retaining rail -3- and outer panel -1- of door together se‐

curely when cutting through adhesive bead further.

– Cut through second half of adhesive bead.

1.9.2

Installing retaining rail

– Using extreme care, cut away remainder of adhesive bead to

the utmost minimum on outer panel of door, ensuring that no

damage is caused to the paintwork.

– Remainder of procedure is described in chapter entitled “In‐

stalling new outer panel for door” 

⇒ page 76

 .

Note

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

when installing a new retaining rail.

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

on the door inner part.

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

retaining rail still in place.

1. Front door    

81

 

hesive tape.

1.10

Installation notes for bonding a new out‐

er panel on door

Note

If front and rear door outer panels must be renewed, they must

be done at the same time. When bonding-in both outer panels,

the long fixing block from assembly tool set -T10237- is stuck

on for the transition from front outer panel to rear outer panel.

If door outer panel CDP coating is damaged on inside in area

to be bonded or it has been painted, this area must be primed

with glass/paint primer -D 009 200 02- .

The 1K glass adhesive -DH 009 100 01- must be heated in

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

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.

– 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- .

Caution

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

hesive properties of adhesive will be impaired.

♦ With assistance of both assembly blocks from assembly tool

set -T10237- , place door outer panel on retaining rails and

align with wedges and setting gauge -3371- and press contact

surfaces of assembly blocks onto adjacent components.

♦ Secure door with fixing blocks from assembly tool set -

T10237- during curing period.

♦ After installation door outer panel must align with other com‐

ponents and gaps 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

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

that a freshly bonded door outer panel must comply with the

safety requirements following the minimum prescribed curing

period, even in an accident.

For door outer panel: curing period for 1K adhesive -DH 009 100

01- is 180 minutes and for 2K adhesive -DA 004 600 A2- 90 mi‐

nutes.

82

 

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 curing period is completed.

1.12

Cleaning off excess adhesive sealing

material

– Use of adhesive remover -D 002 000 10- as a cleaning solution

is recommended. Observe the appropriate safety precautions

when performing this work.

Caution

When  cleaning  vehicle  the  door  outer  panel  just  bonded-in

must not be moved.

– First clean painted surface as much as possible using a dry

cloth. Remove residual excess with adhesive remover -D 002

000 10- .

– Cleaning plastic trim: allow adhesive sealant to cure (approx.

one hour) and then peel off.

1. Front door    

83

 

Note

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

1 - Door inner part
2 - Window slot seal
3 - Loudspeaker
4 - Window regulator motor

❑ Removing 

⇒ page 284

5 - Insulation

❑ Qty. 4
❑ 20 mm x 40 mm com‐

mercially available tex‐

tile adhesive tape

84

 

 

 

 

 

 

 

 

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