Volkswagen Golf Variant / Jetta. Manual - part 31

 

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Volkswagen Golf Variant / Jetta. Manual - part 31

 

 

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 door outer

panels, the long fixing block from assembly tool set -T10237-

is stuck on for the transition from front door outer panel to rear

door 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 outer panel for door 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.

1. Rear door (saloon)    

121

 

nutes.
What is meant by minimum curing period is, time from bonding

outer panel on door to time vehicle is taken into use or further

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.

122

 

Note

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

1 - Window slot seal
2 - Insulation

❑ Qty. 4
❑ 20 mm x 40 mm, com‐

mercially available tex‐

tile adhesive tape.

1. Rear door (saloon)    

123

 

Note

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

1 - Door lock

❑ Removing and installing

⇒ page 129

2 - Cable

❑ To lock release from in‐

terior door handle.

3 - Cover

❑ Not supplied with door

lock.

❑ Secured on door lock

with locking lugs

4 - Bearing bracket

❑ Removing 

⇒ page 127

5 - Torx bolt

❑ 4.5 Nm

6 - Base

❑ Part of door handle.

7 - Door handle with base

❑ Removing and installing

⇒ page 125

8 - Cover

❑ For housing
❑ Secured on housing

with locking lugs

9 - Housing

❑ Removing and installing

⇒ page 124

10 - Base
11 - Torx bolt

❑ For locking housing 

⇒ Item 9 (page 150)

12 - Bolt

❑ 18 Nm

13 - Cable

❑ To release lock from door exterior handle.

1.15

Removing and installing housing

Note

Removal and installation sequence is only for right housing. Re‐

moval and installation of left housing is similar.

124

 

 

 

 

 

 

 

 

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