Golf Mk5 Rear Door

Rear 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

• „ 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

• „ Cartridge heater V.A.G 1939 A

• „ Trim removal wedge 3409

• „ Assembly tool set T 10237

Materials

Table Caption: This table lists automotive glass bonding products, including window adhesive, primer, cleaning solution, and a primer applicator, along with their corresponding part numbers.

3. Materials are stored in box D 004 700.

4. Observe minimum curing time 58-1, Minimum curing time

5. 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 - 4 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 - 1 is also bolted to inner door part on the lower edge. 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
• „ 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

• „ 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 009 100 03

• „ 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 009 100 03

• „ 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

• „ Clip

• „ Qty. 5

• „ Window shaft seal

• „ Must be installed before installing outer door panel.

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.

„ 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

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

• „ 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

• Release boots - 6 by pressing on locking mechanism - arrow a and remove boots from B-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 - 3 and 9 -.

Installing

Installation is performed in the reverse order of removal.

• Tightening torque: Screws - 4, 5 and 11 : 20 Nm + 1 / 4

(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 - 9 - must not be loosened under any circumstances. It cannot be secured again using workshop equipment.

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 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