Volkswagen Golf V - Front door
Page 1 / 44
57 - 1
Front door
Tools
Special tools, testers and auxiliary items
required
„
Socket wrench T 10072
„
Assembly tool T 10118
„
Door adjusting wrench 3320
„
Joint for 3320 3320/1
„
Box wrench 3320/2
Front door
„
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
Page 2 / 44
Front door
Page 3 / 44
„
Cartridge heater V.A.G 1939 A
„
Trim removal wedge 3409
„
Assembly tool set T 10237
Materials
DH 009 100 01 1) 2)
1C- window adhesive
„
„
Glass primer/paint primer
„
Cleaning solution
„
Primer applicator
3) Materials
1) Observe
D 009 401 04 3)
D 009 500 25 3)
are stored in box D 004 700.
minimum curing time
D 009 200 02 3)
57-1, Minimum curing
time
2) Heat
according to manufacturers instructions using
cartridge heater V.A.G 1939 .
Door construction, assembly overview
The door consists of inner door part - 6 and outer door plate - 1 - .
Parts are joined by the front - 7 - and the
rear - 5 - retaining tracks.
Retaining tracks are bolted to inner door
part and bonded to outer door plate.
Inner door part - 6 - undertakes among
other things the function of the previously
known subframe. Loudspeakers, window
regulators, window regulator motors,
wires, window guide, exterior mirror and
door lock are installed on inner door part.
Outer door plate - 1 - is also bolted to
inner door part on the lower edge.
Front door
Page 4 / 44
Exterior window shaft seal, insulation and
outer door handle are installed on outer
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
„
„
Removing and installing
58-1, Outer door plate,
removing and installing
Edge protection
„
Between outer door panel
and inner door part.
Front door
„
„
Screw
„
Characteristic: Bolt has point
and thinner washer.
„
6 pieces on lower edge
„
2 piece in rear rail area
„
10 Nm
Rear retaining track
„
„
„
„
Characteristic: Bolt without
point but with thick washer.
„
Qty. 10 for both retaining
tracks on 4-door version
„
Qty. 11 for both retaining
tracks on 2-door version
„
14 Nm
Inner door part
„
Assembly overview 57-1,
Inner door part, assembly
overview
Front retaining track
„
„
Adhesive: DH 009 100 03
Screw
„
„
Page 5 / 44
Adhesive: DH 009 100 03
Screw
„
Characteristic: Bolt has point
and thick washer
„
Qty. 1 for front rail area
„
10 Nm
Insulation
„
Self-adhesive
Front door
„
„
To adhere, insulation must
be preheated and then
pressed on firmly
Clip
„
„
Page 6 / 44
Qty. 6
Window shaft seal
„
Must be installed before
installing outer door shell.
Door hinges, assembly overview
Caution!
The nut for eccentric pin - 9 - 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.
Front door
„
„
Page 7 / 44
Door
„
Removing and installing
57-1, Door, removing and
installing
„
Adjusting
adjusting
57-1, Door,
Guide bolt
„
10 Nm
„
Door hinge with door arrester
„
Socket head bolt
„
20 Nm + 1 / 4 turn further (90
)
„
Always replace bolts after
Front door
Page 8 / 44
loosening
„
Socket head bolt
„
Installed from the vehicle
interior
„
Remove lower A-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
)
„
„
Guide screws
„
„
10 Nm
Nut
„
„
Always replace bolts after
loosening
For the eccentric pin, must
not be loosened. Used for
making adjustments during
production.
Door hinge
Front door
„
„
Page 9 / 44
Door 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
Front door
- Release boots - 6 - by pressing on
locking mechanism - arrow a - and
remove boots from A-pillar.
- Swivel locking lever - 7 - downward arrow b - and disconnect electrical
harness connector - 8 - 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 - 2 and 9 - .
Installing
Installation is performed in the reverse order of removal.
- Torque specification for screws - 4, 5 and 11 - : 20 Nm +
Page 10 / 44
Front door
1
/ 4 (90
„
Page 11 / 44
) additional turn.
Screws - 4, 5 and 11 - must always be replaced.
- Observe gap dimension of front door
Repair Manual, Body Collision Repair, Repair Group 00,
Technical data; Body gap dimensions
Door, adjusting
Warning!
The nut for eccentric pin - 9 - must
not be loosened under any
circumstances. The nut cannot be
secured again using workshop
equipment.
Front door
Note :
„
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 B-pillar, and to rear door.
- Observe gap dimension of front door
Repair Manual, Body Collision Repair,
Repair Group 00, Technical data; Body
gap dimensions
For correct gap dimension adjustment,
screws - 5, 7, 12 and 13 - at A-pillar
must be loosened. For screw - 5 - ,
lower A-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
Page 12 / 44
Front door
- Pry off clips - 3 - beginning at bottom
of door - 1 - and remove cover - 2 - .
Page 13 / 44
Front door
- Removing lock cylinder
installing
- Remove door handle
installing
Page 14 / 44
57-1, Housing, removing and
57-1, Door handle, removing and
- Remove screw - 1 - from bearing bracket - 2 - , located
behind outer door plate.
- Remove all screws - 2, 3, 4 - .
- 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.
Front door
Page 15 / 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 - 2 - : Bolt has point and
thinner washer.
„
Characteristic for bolt - 3 - : Bolt without point but
with thick washer.
„
Characteristic for bolt - 4 - : 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
Front door
tighten all screws - 2, 3, 4 - .
„
Observe the correct tightening
torques for the various bolts.
Tightening torque for bolt - 2 - : 10 Nm.
Tightening torque for bolt - 3 - : 14 Nm.
Tightening torque for bolt - 4 - : 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 57-1, Installation notes for
adhering a new outer door plate
Page 16 / 44
Front door
„
Old (damaged) outer door plate
with retaining tracks removed
57-1, Outer door plate, removing
and installing
- Install front - 2 - and rear - 6 retaining tracks on inner door part. For
this, use the "bolt without point with thick
washer" .
Torque for bolt - 3 - and - 5 - : 10 Nm.
- Screw two guide screws into bottom
edge of inner door part.
Page 17 / 44
Front door
The painted outer door plate is fitted first
without applying adhesive.
The assembly block from the assembly
tool set T 10237 is needed to fit the outer
door shell. One strip of "Tesa Power
Strips large" - 6 - is affixed onto the
lowered side. The pin has the minimum
dimension for the gap width. The surface
without adhesive is placed onto the
neighboring component until it makes
contact.
- Adhere assembly blocks - 3 - to outer
door plate.
- Guide the outer door plate - 1 - in
lower edge of inner door part via the
guide bolts.
- Using wedges - 4 - from assembly tool
set T 10237 , adjust gap dimension to sill
panel and outer door shell height.
Page 18 / 44
Front door
- Lay outer door panel with assembly
blocks on adjoining components - 2 and
5- .
- Check gap dimension with adjustment
gauge 3371
Repair Manual, Body Collision Repair,
Repair Group 00, Technical data; Body
gap dimensions
- If gap dimensions can no longer be
adjusted, inner door part must be
adjusted 57-1, Door, adjusting
- Remove outer door plate again.
- Apply adhesive beads - 2 - onto front 1 - and rear - 3 - retaining tracks
Page 19 / 44
Front door
cartridge gun V.A.G 1628 .
The securing block from assembly tool
set T 10237 is needed to insert outer
door panel. Two strips of "Tesa Power
Strips large" - 5 - are affixed onto
contact surface.
- Guide the outer door plate - 1 - in
lower edge of inner door part via the
guide bolts.
- Bring outer door plate with assembly
blocks - 3 - into contact with neighboring
components.
- Using wedges - 4 - from assembly tool
set, adjust gap dimension to sill panel
and outer door plate height.
- Check gap dimensions with adjustment
gauge 3371
Page 20 / 44
Front door
Repair Manual, Body Collision Repair,
Repair Group 00, Technical data; Body
gap dimensions
- Affix short securing blocks - 2 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 57-1, 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.
Page 21 / 44
Front door
Outer door plate with retaining tracks removed
Removing
Page 22 / 44
57-1,
- Store the outer door plate - 1 - on a firm surface and
protect outer door plate against scratches.
- Secure spooling tool - 2 - .
- Secure cord - 5 - onto spooling tool and retainer - 4 - .
- Hold retaining track and outer door plate firmly together
when cutting through adhesive bead.
- Using cord, cut through adhesive bead from retaining
track - 3 - and outer door plate - 1 - until slightly out over
the center.
Front door
- After adhesive bead has been cut up to halfway in the
first step, move the spooling tool - 2 - and insert cord - 5 on the side not yet cut.
- Hold retaining track - 3 - and outer door plate - 1 - firmly
together when continuing to cut through adhesive bead.
- Cut through the second half of the adhesive bead.
Installing retaining track
- Carefully, cut 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.
- 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 was
damaged there, this area must be primed using
glass/paint primer D 009 200 02.
„
1K window adhesive DH 009 100 must be heated for
Page 23 / 44
Front door
Page 24 / 44
20 minutes in cartridge heater V.A.G 1939 A .
- Clean application surfaces on retaining tracks with
cleaning solution D 009 401 04.
- 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
Front door
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
prescribed curing time.
The minimum curing time for outer door panel with 1K
adhesive DH 009 100 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
- It is recommended to use adhesive remover D 002 000
10 as a cleaning solution. Observe safety precautions
when processing.
Caution!
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 002 000 10.
- 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.
Page 25 / 44
Front door
Page 26 / 44
„
Inner door part
„
Window shaft seal
„
Loudspeaker
„
Window regulator motor
„
„
removing 64-2, Window
regulator motor, removing
and installing
Insulation
„
4x
„
20 mm x 40 mm
commercially available cloth
reinforced adhesive tape
Front door
Page 27 / 44
Door handle and door lock, assembly overview
Note :
„
The illustration shows the left side. The right side is
similar and can be determined from this.
„
Door lock
„
„
Cable
„
„
Removing and installing
57-1, Door lock, removing
and installing
For disengaging lock of
exterior door handle.
Screw
Front door
„
„
For securing lock to inner
door part
„
18 Nm
„
Qty. 2
Mounting bracket
„
„
Removing and installing
57-1, Bearing bracket,
removing and installing
Screw
„
„
Page 28 / 44
For lock cylinder.
Bolt
„
Not available on all versions.
„
This screw is installed for
additional securing of
mounting bracket.
„
Backing
„
Lock cylinder housing
„
„
„
Only on drivers side.
„
Only one housing is installed
on front passengers side.
„
Removing and installing
57-1, Housing, removing and
installing
Cover cap
„
For the lock cylinder
housing.
„
Is secured to lock cylinder
housing with three tabs.
Key
„
Changing battery 57-2,
Radio-frequency remote
Front door
Page 29 / 44
control key (foldable) battery
- assembly overview
„
„
Door handle with backing plate
„
„
Not installed in Rabbit/GTI.
Cable
„
„
Not installed in Rabbit/GTI.
Angle bracket
„
„
Socket wrench T 10072
Expanding rivet
„
„
Is a component of door
handle.
Torx screw
„
„
Removing and installing
57-1, Door handle, removing
and installing
Backing
„
„
Adapting new/additional
keys to remote control and
immobilizer 57-2,
Adaptation of keys with
radio-frequency remote
control
To lock release mechanism
of door handle.
Cover
„
Does not belong to
packaged contents of door
lock
„
Is secured to door lock with
three tabs.
Front door
Housing, removing and installing
Note:
„
Removing and installing is described only for the
housing. Removing and installing lock cylinder is
derived accordingly from this.
Removing
- Pry out cover cap in front of bolt - 1 - .
- Pull door handle - 2 - in - direction of arrow - and turn
screw - 1 - with socket wrench T 10072 until housing - 3 can be removed.
Installing
- Insert housing - 3 - in right angle - arrow - into door
handle bearing bracket.
Door handle - 2 - must make contact only lightly at door
plate.
- Install the bolt - 1 - into bearing bracket using socket
wrench T 10072 .
Door handle - 2 - engages again into housing - 3 - with a
Page 30 / 44
Front door
Page 31 / 44
very audible click.
Note:
„
During installation, housing must be pressed onto
door plate. The door handle rests only lightly against
the door panel.
Further installation is 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
- Remove housing
installing .
57-1, Housing, removing and
- Pry out clip - 2 - from door handle - 1 - .
- Swivel door handle - 1 - out of door - arrow - .
Installing
Front door
- Guide assembly tool T 10118 into door
through opening in inner door plate.
- Light the inner part of door using a
flashlight for better view.
- Hook assembly tool T 10118 into
spring - arrow A - .
- Engage spring into door lock by pulling
assembly tool T 10118 - arrow B - .
Release lever is now locked in position.
Note :
„
Lock is secured by engaging spring in the operating
lever. This prevents the cable from subsequently
being clipped in at door handle incorrectly.
Page 32 / 44
Front door
Page 33 / 44
- Swivel door handle - 1 - into door.
- Pull clip - 2 - into plate cutout and engage clip into door
handle - 1 - - arrow - .
Note:
„
During installation, door handle - 1 - must be
pressed onto door plate.
„
Clip - 2 - must engage into door handle - 1 - with a
very audibly click.
Install housing
„
57-1, 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 and installing
Note:
„
Removing and installing is described only for the
right bearing bracket. Removing and installing the
left bearing bracket is derived accordingly from this.
Removing
Front door
- Remove lock cylinder housing
Housing, removing and installing
Page 34 / 44
57-1,
- Remove door handle 57-1, Door
handle, removing and installing
- Remove outer door panel 58-1,
Outer door plate, removing and
installing
- Pull retaining rubber - 4 - upward from
guide pin.
- Pull bearing bracket - 1 - in - direction
of arrow - with guide pin - 2 - out of
mounts - 3 - .
Installing
Front door
- Slide bearing bracket - 1 - with guide
pin - 2 - into mounts - 3 - .
- Secure retaining rubber - 4 - on guide
pin and mounting pin on bearing bracket
mount.
Further installation is in reverse order of
removal.
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
Page 35 / 44
Front door
- Remove outer door panel 58-1,
Outer door plate, removing and
installing
- Remove mounting bracket 57-1,
Bearing bracket, removing and installing
- Disconnect connector - 5 - .
- Remove bolts - 6 - .
- Disengage cable - 1 - from actuator
lever - 8 - and remove door lock - 4 - .
Cover - 3 - 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.
Page 36 / 44
Front door
„
Page 37 / 44
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
„
Side impact protection
„
Screw
„
4x
Front door
„
Page 38 / 44
20 Nm
„
Insulation
„
Nut
„
Qty. 2
„
20 Nm
Inner door seal
Inner door seals are equipped at the factory with sealant,
applied to door flange and then rolled on.
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 left
inner door seal. Removing and installing the right
inner door seal is derived accordingly from this.
Removing
Front door
- Pull off inner door seal from body
flange.
Installing
Page 39 / 44
Front door
- 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.
„
Adhesive remover D 002 000 10 is to be used
Page 40 / 44
Front door
exclusively.
„
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
Page 41 / 44
Front door
- Remove any adhesive residue still
present using radial disc for streak
remover Z 432 290 TE
- Thoroughly clean the adhesion surface
with adhesive remover D 002 000 10
immediately before adhering the outer
door seal.
„
Adhesion surfaces must be free of
dust and grease and there must be
no residual adhesive present.
- Align outer door seal with cut-out arrow b - with door lock securing
screw.
- Vulcanized point - arrow c - of outer
door seal is then located in center area of
door entry sill.
- Pull off foil cover and apply seal onto
Page 42 / 44
Front door
door. Do not stretch outer door seal
excessively so that the seal is not too
long at the end.
- Press entire adhesive area of seal all
around onto door using application roller
3356 , starting in upper radius - arrow a
- of door.
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.
- Place seal - 1 - facing outward by
Page 43 / 44
Front door
hand.
- If adhered area does not pull off in any
areas, press seal on further once more
using application roller 3356 .
Page 44 / 44