Outer Door Panel
Outer Door Panel
Installing New Outer Door Panel, refer to
Old Outer Door Panel
Removing
- Pry out clips - 3 - starting from bottom on door - 1 - and remove cover - 2 -.
- Remove lock cylinder. Refer to => [ Housing ] Housing.
- Remove door handle. Refer to => [ Door Handle ] Door Handle.
- Remove bolt - 1 - from bearing bracket - 2 -, located behind outer door panel.
- Remove all bolts - 2 -, - 3 - and - 4 -.
• On some vehicles, bolt - 4 - may be installed instead of bolt - 2 - on the top rear of the door. If this is the case, do not replace bolt - 4 - with bolt - 2 -.
- Carefully remove outer door panel.
Installing
Various bolts are used to secure the outer door panel. Outer door panel is damaged if not allocated correctly.
- Carefully insert outer door panel.
- Install all bolts - 2 -, - 3 - and - 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 and has thicker washer
• Characteristic for bolt - 4 -: Bolt has point and thicker washer
- Check whether guide pins for retaining tracks are located in the corresponding guide holes of door inner part. Only then tighten all bolts - 2 -, - 3 - and - 4 -.
Observe the correct tightening torques for the various bolts.
Tightening specification for bolt - 2 -: 10 Nm
Tightening specification for bolt - 3 -: 14 Nm
Tightening specification for bolt - 4 -: 10 Nm
Further installation is performed in the reverse order of removal.
New Outer Door Panel
Various bolts are used to secure the outer door panel. Outer door panel is damaged if not allocated correctly.
• Observe the chapter of installation notes, bonding new outer door panel. Refer to => [ Outer Door Panel Installation Information ] Outer Door Panel Installation Information.
• Damaged outer door panel with retaining tracks removed. Refer to => [ Outer Door Panel ].
- Install front - 2 - and rear - 6 - retaining tracks on door inner part - 1 -. Use the "bolt without point with thick washer".
Tightening specification for bolt - 3 - and - 5 -: 14 Nm
- Screw two guide bolts - 4 - into lower edge of door inner part - 1 -.
The painted outer door panel is fitted first without applying adhesive.
To fit the outer door panel, assembly blocks - 3 - from assembly tool set (T10237) are required. A strip of double-sided tape - 6 - is attached to 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 - onto outer door panel - 1 -.
- Guide the outer door panel - 1 - in lower edge of door inner part via the guide bolts.
- Using wedges - 4 - from assembly tool set (T10237), adjust gap dimension to sill panel and outer door panel height.
- Place outer door panel - 1 - with assembly blocks onto neighboring components - 2 - and - 5 -.
- Check gap dimension using adjusting gauge (3371).
If gap dimensions can no longer be adjusted, door inner part must be adjusted. Refer to => [ Adjusting Door ] Adjusting Door.
- Remove outer door panel again.
- Apply adhesive beads - 2 - onto the front - 1 - and rear - 3 - retaining tracks using the Cartridge Gun (V.A.G 1628).
• For this step, it is also possible to use the (DA 004 600 A2) adhesive, which is applied with a Double Cartridge Gun (VAS 5237). Pre-warming is not applicable here.
To insert the outer door panel, securing blocks - 2 - from assembly tool set (T10237) are required. Two strips of double-sided tape - 5 - are applied to the contact surface.
- Guide the outer door panel - 1 - in lower edge of door inner part via the guide bolts.
- Bring outer door panel 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 panel height.
- Check gap dimensions using adjusting gauge (3371).
- Install short securing blocks - 2 - uniformly onto door to be replaced and neighboring components.
• A waiting time of 90 or 180 minutes must be observed before performing further work on the bonded door. Refer to => [ Minimum Curing Time ] Minimum Curing Time.
- Rest of installation for outer door panel is the reverse of removal.
