Installation Notes For Bonding A New Outer Panel On Door; Minimum Curing Period - Volkswagen Jetta 2005 Workshop Manual

Golf Variant 2007 ➤ , Jetta 2005 ➤
General body repairs, exterior - Edition 10.2009
– Secure outer panel for door on new retaining rail with fixing
blocks from assembly tool set -T10237- and double-sided ad‐
hesive tape.
1.10 Installation notes for bonding a new out‐
er panel on door
Note
If front and rear door outer panels must be renewed, they must
♦
be done at the same time. When bonding-in both outer panels,
the long fixing block from assembly tool set -T10237- is stuck
on for the transition from front outer panel to rear outer panel.
If door outer panel CDP coating is damaged on inside in area
♦
to be bonded or it has been painted, this area must be primed
with glass/paint primer -D 009 200 02- .
The 1K glass adhesive -DH 009 100 01- must be heated in
♦
cartridge heater -V.A.G 1939 A- for 20 minutes.
Adhesive -DA 004 600 A2- can be used for this procedure and
♦
is applied with double cartridge gun -VAS 5237- . There is no
requirement to preheat.
– Clean contact surfaces on retaining rails thoroughly using
cleaning solution -D 009 401 04- .
– Apply adhesive material to appropriate surfaces at right angles
to retaining rail using cartridge gun -V.A.G 1628- .
Caution
Door outer panel must be installed within 10 minutes, or ad‐
hesive properties of adhesive will be impaired.
♦ With assistance of both assembly blocks from assembly tool
set -T10237- , place door outer panel on retaining rails and
align with wedges and setting gauge -3371- and press contact
surfaces of assembly blocks onto adjacent components.
♦ Secure door with fixing blocks from assembly tool set -
T10237- during curing period.
♦ After installation door outer panel must align with other com‐
ponents and gaps must be even.
♦ If adhesive bead is too thick and adhesive exudes between
retaining rail and door outer panel, excess adhesive must be
removed.
1.11

Minimum curing period

WARNING
Special standards must be adhered to when replacing bonded
outer panels for door. One of these standards is, for example,
that a freshly bonded door outer panel must comply with the
safety requirements following the minimum prescribed curing
period, even in an accident.
For door outer panel: curing period for 1K adhesive -DH 009 100
01- is 180 minutes and for 2K adhesive -DA 004 600 A2- 90 mi‐
nutes.
82
Rep. Gr.57 - Front doors, door components, central locking