Installing new outer door panel: VW Golf V / Jetta

🧭 Before you start

Fits: VW Golf V / Jetta (1K, 2003–2009)

Don't miss

• If gap dimension cannot be adjusted, door inner part must be adjusted
• A waiting time of 180 minutes must be observed before performing further work on the bonded door.

📋 Procedure

1. ⚠ Bolts of different types are used to secure outer door panel. If these are fitted in the wrong positions, the outer door panel will be damaged. — Install front (2) and rear (6) retaining rails to door inner part. Use "“bolt with no point but with thicker washer”" for this.
2. Fit two guide bolts in lower edge of door inner part.
3. Bond the edge protection in position.
4. Bond assembly block (3) on outer door panel.
5. Guide outer door panel (1) over guide bolts in lower edge of door inner part.

6. Adjust gap to side member and outer door panel height using wedges (4) from assembly tool setT 10237.
7. Place outer door panel with assembly blocks on surrounding components (2 and 5).
8. Check gap dimension using setting gauge337100Technical data; Body gap dimensions.
9. If gap dimension cannot be adjusted, door inner part must be adjusted
10. Remove outer door panel again.
11. Apply a bead of adhesive material (2) using cartridge gunV.A.G 1628 to front (1) and rear (3) retaining rails.
12. Guide outer door panel (1) over guide bolts in lower edge of door inner part.
13. Place outer door panel with assembly blocks (3) on surrounding components.
14. Adjust gap to side member and outer door panel height using wedges (4) from assembly tool set.
15. Check gap dimensions using setting gauge337100Technical data; Body gap dimensions.
16. Bond short fixing blocks (2) evenly on the replacement door and the adjacent components. [Note: A waiting time of 180 minutes must be observed before performing further work on the bonded door.]
17. Further installation is performed in the reverse order of removal .

Other VW procedures

• Removing engine · 41 torque figures
• Removing and installing camshaft – VW Golf Cabriolet · 47 torque figures
• Adjusting valve timing – VW Passat B5 · 83 torque figures
• Removing and installing camshafts – VW Passat B6 · 39 torque figures
• Removing and installing coolant pump · 53 torque figures
• Servicing clutch
• Hydraulic unit, brake servo/brake master cylinder - Assembly overview, Mark 60
• Repairing air conditioning and heating - passenger compartment
• Repairing air conditioning and heating - engine compartment
• Coding airbag control unit J234 with fault reader V.A.G 1551