Volkswagen Golf Variant / Jetta. Manual - part 30

 

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Volkswagen Golf Variant / Jetta. Manual - part 30

 

 

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.

1. Rear door (saloon)    

117

 

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 121

 .

– Further installation is performed in reverse order of removal

⇒ page 114

 .

118

 

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.

1. Rear door (saloon)    

119

 

 .

– 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 115

 .

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 part.

– Apply adhesive to new retaining rail
– Secure outer panel for door to lower edge and fitted retaining

rail.

120

 

 

 

 

 

 

 

 

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