New Outer Door Panel

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 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.

Fig 1: Applying Adhesive Material All Around Onto Pre-Coating

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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.