Installing new outer panel on door — VW

🧭 Before you start

Fits: platform codes 5M1, 521

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• If gap dimension cannot be adjusted, door inner part must be adjusted
• The Golf Plus has retaining rails made from metal; these must be primed using glass/paint primer D 009 200 02.
• A waiting time of 90 minutes must be observed before performing further work on the bonded door.

📋 Procedure

1. ⚠ Different securing screws are used for the door outer panel. If these are fitted in the wrong positions, the outer panel for the door will be damaged. — Install front (2) and rear (6) retaining rails on inner part of door. 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 assembly block (3) on door outer panel.
4. Guide outer panel (1) over guide bolts on lower edge of door inner part.
5. Adjust gap to side member and height of outer panel on door using wedges (4) from assembly tool setT 10237.

6. Lay door outer panel with assembly blocks on adjacent components (2 and 5).
7. Check gap/shut lines using setting gauge337100Body panel gaps/shut lines
8. If gap dimension cannot be adjusted, door inner part must be adjusted
9. Remove door outer panel again. [Note: The Golf Plus has retaining rails made from metal; these must be primed using glass/paint primer D 009 200 02.]
10. Apply a bead of adhesive material (2) using cartridge gunV.A.G 1628 to front (1) and rear (3) retaining rails.
11. Guide outer panel (1) over guide bolts on lower edge of door inner part.
12. Place outer door panel with assembly blocks (3) on surrounding components.
13. Adjust gap to side member and height of outer panel on door using wedges (4) from set.
14. Check gap/shutline using setting gauge337100Body gaps/shutlines
15. Bond short fixing blocks (2) evenly on the replacement door and the adjacent components. [Note: A waiting time of 90 minutes must be observed before performing further work on the bonded door.]
16. Further installation is performed in the reverse order of removal .

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