Rear door. Volkswagen Golf 5 - Rear door. Special tools, testers and auxiliary items required. Socket wrench T Assembly tool T 10118

Transcription

1 Volkswagen Golf 5 - Rear door Page 1 / Rear door Tools Special tools, testers and auxiliary items required Socket wrench T Assembly tool T Door adjusting wrench 3320 Joint for /1 Box wrench 3320/2

2 Page 2 / 44 Box wrench 3320/3 Application roller for door insulation foil 3356 Torque wrench 550 Nm V.A.G 1331 Adjusting gauge 3371 Special tools, testers and auxiliary items required Cartridge gun V.A.G 1628

3 Page 3 / 44 Cartridge heater V.A.G 1939 A Trim removal wedge 3409 Assembly tool set T Materials 1C- window adhesive Glass primer/paint primer Cleaning solution Primer applicator DH D ) D ) D ) 1) 2) 3) Materials are stored in box D ) Observe minimum curing time 58-1, Minimum curing time 2) Heat according to manufacturers instructions using cartridge heater V.A.G Door construction, assembly overview The door consists of inner door part and outer door plate Parts are joined by the front and the rear retaining tracks. Retaining tracks are bolted to inner door part and bonded to outer door plate. Loudspeakers, window regulators, window regulator motors, wires, window guide and door lock are installed on inner door part. Outer door plate is also bolted to inner door part on the lower edge. Exterior window shaft seal, insulation and outer door handle are installed on outer

4 Page 4 / 44 door plate. Caution! Various bolts are used to secure the outer door plate. Outer door plate is damaged if not allocated correctly. Outer door plate Outer door plate, removing and installing 58-1, Outer door plate, removing and installing Edge protection Between outer door panel and inner door part. Screw

5 Page 5 / 44 Characteristic: Bolt has point and thinner washer. 4 pieces on lower edge 2 piece in rear rail area 10 Nm Rear retaining track Adhesive: DH Screw Characteristic: Bolt without point but with thick washer. 11 pieces on both retaining tracks 14 Nm Inner door part Assembly overview 58-1, Inner door part, assembly overview Front retaining track Adhesive: DH Screw Characteristic: Bolt has point but thick washer. Qty. 1 for front rail area 10 Nm Insulation Self-adhesive To adhere, insulation must be preheated and then pressed on firmly

6 Page 6 / 44 Clip Qty. 5 Window shaft seal Must be installed before installing outer door panel. Door hinges, assembly overview Caution! The nut for eccentric pin must not be loosened under any circumstances. It cannot be secured again using workshop equipment. Note : The description applies to the right side. The left side is derived accordingly from this. Bolts for door hinges must always be replaced after loosening. Hinges are no longer manufactured as separated parts.

7 Page 7 / 44 Door Removing and installing 58-1, Door, removing and installing Adjusting 58-1, Door, adjusting Guide bolt 10 Nm Door hinge with door arrester Socket head bolt 20 Nm + 1 / 4 turn further (90 ) Always replace bolts after

8 Page 8 / 44 loosening Socket head bolt Installed from the vehicle interior Remove lower B-pillar trim Repair Manual, Body Interior, Repair Group 70, Trim panels/insulation; Pillar and side trim 20 Nm + 1 / 4 turn further (90 ) Always replace bolts after loosening Socket head bolt 20 Nm + 1 / 4 turn further (90 ) Always replace bolts after loosening Socket head bolt 20 Nm + 1 / 4 turn further (90 ) Always replace bolts after loosening Guide bolt 10 Nm Nut For the eccentric pin, must not be loosened. Used for making adjustments during production. Door hinge

9 Page 9 / 44 Hinge is no longer manufactured as separated parts. Socket head bolt 20 Nm + 1 / 4 turn further (90 ) Always replace bolts after loosening Socket head bolt 20 Nm + 1 / 4 turn further (90 ) Always replace bolts after loosening Socket head bolt 20 Nm + 1 / 4 turn further (90 ) Always replace bolts after loosening Door, removing and installing Note: Removing and installing is described only for the right door. Removing and installing the left door is derived accordingly from this. Removing

10 Page 10 / 44 - Release boots by pressing on locking mechanism - arrow a - and remove boots from B-pillar. - Swivel locking lever downward - arrow b - and disconnect electrical harness connector from connector station. - Remove screws - 4, 5 and 11 - using door adjustment wrench 3320 and bit insert 3320/3 from hinge. - Pull door in - direction of arrow - from guide bolts - 3 and 9 -. Installing Installation is performed in the reverse order of removal. - Tightening torque: Screws - 4, 5 and 11 - : 20 Nm + 1 / 4

11 Page 11 / 44 (90 ) additional turn Screws - 4, 5 and 11 - must always be replaced. - Observe gap dimension of rear door Repair Manual, Body Collision Repair, Repair Group 00, Technical data; Body gap dimensions Door, adjusting Caution! The nut for eccentric pin must not be loosened under any circumstances. It cannot be secured again using workshop equipment. Note :

12 Page 12 / 44 The door is properly adjusted when there is an overall even gap dimension when closed, it is not too far inward or outward and contours align. Vehicle must stand on its wheels in order to be able to perform the adjustment. If outer door plate is removed, window frame of inner door part must be adjusted in relation to roof frame and C-pillar, and front door. - Observe gap dimension of rear door Repair Manual, Body Collision Repair, Repair Group 00, Technical data; Body gap dimensions To adjust the gap dimension correctly screws - 5, 7, 12 and 13 - must be loosened. For screw - 5 -, lower B-pillar trim must be removed Repair Manual, Body Interior, Repair Group 70, Pillar and side trim. Other measures, such as aligning the door upward, are not effective. Excess pressure thereafter will again cause the door to sag. For correct alignment adjustment, screws - 4, 6 and 14 - and guide screws - 2 and 8 - must be loosened. Door adjusting wrench 3320 with bit insert 3320/3 must be used for this. Outer door plate, removing and installing Removing

13 Page 13 / 44 - Pry off clips beginning at bottom of door and remove rear cover Pry off clips beginning at bottom of door and remove rear cover

14 Page 14 / 44 - Removing lock cylinder housing: 57-1, Housing, removing and installing. - Remove door handle 57-1, Door handle, removing and installing - Remove screw from bearing bracket - 2 -, located behind outer door plate.

15 Page 15 / 44 - Remove all screws - 2, 3 and Carefully remove outer door plate. Installing Caution! Various bolts are used to secure the outer door plate. Outer door plate is damaged if not allocated correctly.

16 Page 16 / 44 - Carefully set outer door plate in. - Start all screws - 2, 3, 4 -. Make sure that the various bolts are used correctly. Characteristic for bolt : Bolt has point and thinner washer. Characteristic for bolt : Bolt without point but with thick washer. Characteristic for bolt : Bolt has point and thick washer - Check whether guide pins for retaining tracks are located in the corresponding guide holes of inner door part. Then

17 Page 17 / 44 tighten all screws - 2, 3, 4 -. Observe the correct tightening torques for the various bolts. Tightening torque for bolt : 10 Nm. Tightening torque for bolt : 14 Nm. Tightening torque for bolt : 10 Nm. Further installation is performed in the reverse order of removal. New outer door plate, installing Caution! Various bolts are used to secure the outer door plate. Outer door plate is damaged if not allocated correctly. Note: Observe the chapter of installation notes, bonding new outer door plate 58-1, Installation notes for adhering a new outer door plate

18 Page 18 / 44 Old (damaged) outer door plate with retaining tracks removed 58-1, Outer door plate, removing and installing - Install front and rear retaining tracks on inner door part. For this, use the "bolt without point with thick washer". Torque for bolt and : 10 Nm. - Screw two guide screws into bottem edge of inner door part.

19 Page 19 / 44 The painted outer door plate is fitted first without applying adhesive. The assembly block from the assembly tool set T is needed to fit the outer door plate. One strip of "Tesa Power Strips large" is affixed onto the lowered side. The pin has the minimum dimension for the gap dimension. The surface without adhesive is placed onto the neighboring component until it makes contact. - Adhere assembly blocks to outer door plate. - Guide the outer door plate in lower edge of inner door part via the guide bolts. - Using wedges from assembly tool set T 10237, adjust gap dimension to sill panel and outer door plate height.

20 Page 20 / 44 - Lay outer door panel with assembly blocks on adjoining components - 2 and Check gap dimension with adjustment gauge 3371 Repair Manual, Body Collision Repair, Repair Group 00, Technical data; Body gap dimensions - If gap dimensions can not be adjusted, inner door part must be adjusted 58-1, Inner door part, assembly overview - Remove outer door plate again. - Apply adhesive beads onto front and rear retaining tracks

21 Page 21 / 44 cartridge gun V.A.G The assembly block from the assembly tool set T is needed to insert the outer door plate. Two strips of "Tesa Power Strips large" are affixed onto contact surface. - Guide the outer door plate in lower edge of inner door part via the guide bolts. - Place outer door panel with assembly blocks on adjacent components. - Using wedges from set, adjust gap dimension to sill panel and outer door shell height. - Check gap dimensions with adjustment gauge 3371

22 Page 22 / 44 Repair Manual, Body Collision Repair, Repair Group 00, Technical data; Body gap dimensions - Affix short securing blocks uniformly onto door to be replaced and neighboring components. Note: A waiting time of 180 minutes must be observed before performing further work on the affixed door. - Rest of installation is performed in the reverse order of removal 58-1, Installing Retaining track on outer door plate, removing and installing Removing retaining track Caution! The following work must be performed very carefully. Since the outer door plate is to be re-used, dents and scratches must be prevented. When cutting through adhesive bead, always hold retaining track and outer door plate together as shown in the illustration. Otherwise, outer door plate flaps off the retaining track and must no longer be used again. Note: The following work is to be performed only with a second technician.

23 Page 23 / 44 Outer door plate with retaining tracks removed 58-1, Removing - Store the outer door plate on a firm surface and protect outer door plate against scratches. - Secure spooling tool Secure cord onto spooling tool and retainer Hold retaining track and outer door plate firmly together when cutting through adhesive bead. - Using cord, cut through adhesive bead from retaining track and outer door plate until slightly out over the center.

24 Page 24 / 44 - After adhesive bead has been cut up to halfway in the first step, move the spooling tool and insert cord on the side not yet cut. - Hold retaining track and outer door plate firmly together when continuing to cut through adhesive bead. - Cut through the second half of the adhesive bead. Installing retaining track - With utmost care, cut down remaining adhesive bead on outer door plate up to the highest possible minimum without damaging paintwork while doing so. - Further work steps are described in chapter "installing new outer door plate" 57-1, New outer door plate, installing. Note: "Installation notes for adhering new outer door plate" are also to be followed to install a new retaining track. - Install a new retaining track onto inner door part on location of the removed retaining track. - Apply adhesive onto the new retaining track. - Firmly bolt door plate on lower edge and on the retaining track not cut. - Secure outer door panel to new retaining track with securing blocks. Installation notes for adhering a new outer door plate Note: If both outer door plates must be replaced on a side, follow the sequence. First the rear outer door plate and then the front outer door plate is aligned and adhered. For alignment of rear outer door panel to front outer door panel, adhere long securing blocks. If the cataphoretic paint coating of outer door plate is damaged on the inside in the adhesion area or if there is paint there, this area must be primed using glass/paint primer D K window adhesive DH must be heated for

25 Page 25 / minutes in cartridge heater V.A.G 1939 A. - Apply adhesive material using cartridge gun V.A.G 1628 onto application surfaces at a right angle to the retaining track. Warning! Outer door plate must be installed within 10 minutes, otherwise bonding properties of adhesive will be impaired. Place outer door panel on retaining tracks with help of both assembly blocks, center with wedges and adjustment gauge 3371 and press assembly block application surfaces onto surrounding components. Secure outer door panel during curing time with securing blocks. After installing, align outer door plate to the other components and gap dimensions must be uniform. If the adhesive bead has been applied too thickly and the adhesive expands out between retaining track and outer door plate, then the excess adhesive must be removed. Minimum curing time Warning! Special requirements must be fulfilled for replacing bonded outer door plates. One of these standards for example is, that a freshly bonded outer door plate must comply with the safety elements, even in an accident, once the adhesive has exceeded the

26 Page 26 / 44 prescribed curing time. The minimum curing time for outer door panel with 1K adhesive DH is 180 minutes. By minimum curing time, it is meant the time from bonding in the outer door plate up to use in the vehicle, or until further work can be performed. During this time, the vehicle must stand on an even surface at room temperature (at least 15 C). Warning! The vehicle is operationally ready only after the minimum curing time has elapsed. Cleaning when soiled by adhesive sealing material - Adhesive remover D is to be used as a cleaning solution. Observe safety precautions when processing. Warning! When cleaning the vehicle, outer door plate bonded in immediately beforehand must not be shifted. - First clean paint surface coarsely using a dry rag. Eliminate remaining soiling using adhesive removal solution D Clean plastic trim: Allow adhesive sealing material to harden (about 1 hour) and then peel off. Inner door part, assembly overview Note : The description applies to the right side. The left side is derived accordingly from this.

27 Page 27 / 44 Window shaft seal Insulation Qty mm x 40 mm commercially available cloth reinforced adhesive tape Door handle and door lock, assembly overview Note : The description applies to the right side. The left side is derived accordingly from this.

28 Page 28 / 44 Door lock Door lock can only be removed in conjunction with the outer door plate. Removing and installing 58-1, Door lock, removing and installing Angle bracket Not installed in Rabbit/GTI. Expanding rivet Not installed in Rabbit/GTI. Cable

29 Page 29 / 44 For disengaging lock of interior door handle. Cover Does not belong to packaged contents of door lock Is secured to door lock with three tabs. Mounting bracket Removing 58-1, Bearing bracket, removing Screw Backing Component of door handle Door handle with backing plate Removing and installing 58-1, Door handle, removing and installing Cover cap For lock cylinder housing without opening for lock cylinder. Is secured to lock cylinder housing with three tabs. Housing Removing and installing 58-1, Housing, removing and installing Without lock cylinder. Backing Torx screw

30 Page 30 / 44 Socket wrench T By loosening this bolt, locking mechanism for the housing Item is disengaged and may be removed from mounting bracket. Screw 18 Nm Cable For disengaging lock of exterior door handle. Housing, removing and installing Note: Removing and installing is described only for the right housing. Removing and installing the left housing is derived accordingly from this. Removing - Pry out cover cap in front of bolt Pull door handle in - direction of arrow - and turn screw with socket wrench T until housing can be removed. - Remove housing at right angle to door from door handle bearing bracket.

31 Page 31 / 44 Installing - Insert housing at right angle into door handle mounting bracket. Door handle must make contact only lightly at door plate. - Now screw in the bolt into bearing bracket using socket wrench T Door handle engages again into lock cylinder housing with a very audible click. Note: During installation, housing must be pressed onto door plate. The door handle rests only lightly against the door panel. - Then, continue in reverse order of removal. Then a function test must be performed with door open, since the door cannot be opened if hood release cable is not correctly adjustment or clipped in. Door handle, removing and installing Note: Removing and installing is described only for the right door handle. Removing and installing the left door handle is derived accordingly from this. Removing

32 Page 32 / 44 - Removing housing: 58-1, Housing, removing and installing. - Pry out clip from door handle Swivel door handle out of door - arrow-. Installing - Guide assembly tool T into door

33 Page 33 / 44 through opening in inner door plate. - Light the inner part of door using a flashlight for better view. - Hook assembly tool T into spring - arrow A -. - Engage spring into door lock by pulling assembly tool T arrow B -. Release lever is now locked in position. - Swivel door handle into door. - Pull clip into plate cutout and engage clip into door handle arrow -. Note: During installation, door handle must be pressed onto door plate. Clip must engage into door handle with a very audibly click. Install housing 58-1, Installing Then a function test must be performed with door open, since the door cannot be opened if hood release cable is not correctly adjustment or clipped in. Bearing bracket, removing Note: Removing and installing is described only for the

34 Page 34 / 44 right bearing bracket. Removing and installing the left bearing bracket is derived accordingly from this. Removing - Remove housing 58-1, Housing, removing and installing - Remove door handle: 58-1, Door handle, removing and installing - Remove outer door panel: 58-1, Outer door plate, removing and installing - Pull off retaining rubber from guide pin and retaining bolts on mount upward. - Pull bearing bracket with guide pin out of mounts Installing

35 Page 35 / 44 - Slide bearing bracket with guide pin into mounts Secure retaining rubber on guide pin and retaining bolts on mount. Door lock, removing and installing Note: Removing and installing is described only for the right door lock. Removing and installing the left door lock is derived accordingly from this. Removing

36 Page 36 / 44 - Remove outer door panel 58-1, Removing - Remove mounting bracket 58-1, Bearing bracket, removing - Disconnect harness connector Remove bolts Disengage cable from actuator lever and remove door lock Cover is not supplied with delivery casing of door lock. Installing Installation is performed in the reverse order of removal. Tightening torques for bolts: 18 Nm Then a function test must be performed with door open, since the door cannot be opened if hood release cable is not correctly adjustment or clipped in. Side impact protection, assembly overview Caution! The side impact member screws and nuts are painted during production. That means that the threads could shear off during removal with significant force. Loosening of screws and nuts should be avoided when possible

37 Page 37 / 44 Side impact protection Bolts Qty Nm Nut Qty Nm Inner door part Internal door seals Inner door seals are equipped at the factory with sealant, applied to door flange and then rolled on.

38 Page 38 / 44 Note: During removal of the seal, sealant is distributed on interior side of seal and flanks are bent up easily. If the seal is re-installed, the sealing performance and proper seating are no longer guaranteed. For this reason, every completely removed seal must be replaced with a so-called "hammer-stroke seal". For partially removed seals, seal flanks must be pressed together before installation. Inner door seal, removing and installing Note: Removing and installing is described only for the right inner door seal. Removing and installing the left inner door seal is derived accordingly from this. Removing

39 Page 39 / 44 - Pull off inner door seal from body flange. Installing

40 Page 40 / 44 - Align inner door seal with vulcanized point - arrow b - at the height of the lower hinge. - Start installation of inner door seal in upper radius - arrow a - of door opening. Outer door seal, removing and installing Note: Removing and installing is described only for the right outer door seal. Removing and installing the left outer door seal is derived accordingly from this. Remove protective foil only immediately prior to assembly. Processing temperature approx. 20 C. It is exclusively adhesive remove D

41 Page 41 / 44 The outer door seal must be applied immediately after cleaning. After 10 minutes, check the seal for a secure fit. Removing - Pull off outer door seal from door Installing

42 Page 42 / 44 - Remove any adhesive residue that is still present using the erasure disc for stripe remover erase disc Z TE. - Always clean adhesion surface immediately prior to adhering outer door seal with adhesive removal solution D Adhesion surfaces must be free of dust and grease and there must be no residual adhesive present. - Vulcanized point - arrow b - of outer door seal is located in center area of door entry sill. - Pull off foil cover and apply seal onto door in upper radius - arrow a -. Do not stretch outer door seal excessively so that the seal is not too long at the end.

43 Page 43 / 44 - Press entire adhesive area of seal onto door all around using application roller After 10 minutes, perform test for proper seal seating. Note : Part numbers are for reference only. Always check with your Parts Department for the latest part number information Checking seal for secure seating Check seal for firm setting 10 minutes after adhering the seal. - Try to put seal outward by hand. - If adhered area does not pull off in any

44 Page 44 / 44 areas, press seal on further once more using application roller 3356.