Door Construction Assembly Overview

A new door concept was introduced for the Rabbit/GTI/R32.

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. Speakers, window regulators, window regulator motors, wires, window guide, exterior rearview mirror and door lock are installed on the inner part of the door.

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.

Fig 1: Door Construction, Assembly Overview

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

1. Outer door plate
   • Removing and Installing OUTER DOOR PANEL
2. Edge protection
   • Between outer door panel and inner door part.
3. Bolt
   • Characteristic: Bolt has point and thinner washer.
   • 6 pieces on lower edge
   • 2 piece in rear rail area
   • 10 Nm
4. Rear retaining track
   • Adhesive: DH 009 100 03
5. Bolt
   • 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
6. Inner door part
   • Assembly overview INNER DOOR PANEL ASSEMBLY OVERVIEW 
7. Front retaining track
   • Adhesive: DH 009 100 03
8. Bolt
   • Characteristic: Bolt has point and thick washer
   • Qty. 1 for front rail area
   • 10 Nm
9. Insulation
   • Self-adhesive
   • To adhere, insulation must be preheated and then pressed on firmly
10. Clip
    • Qty. 6
11. Window shaft seal
    • Must be installed before installing outer door shell.