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Replacing A-pillar side hinge half > < Renewing front door

Leon Mk2

Replacing door-side hinge half
Replacing door-side hinge half
–  Adjust replacement door and establish if there are any differences in hinge clearance/height. One or both of the door side hinge halves may require replacement.
   
–  Mark the point where the service door hinge -2- is to be drilled and make a corresponding mark on the door hinge to be replaced -1-, centre-punch.
  N57-0334
–  Drill 4 mm Ø hole through old door hinge and door reinforcement.
  N57-0335
–  Grind through weld seams of old door hinge using electronic angle grinder -V.A.G 1528 A-.
–  Take off door hinge and remove residual weld seams.
–  Drill 9 mm Ø holes in door
  N57-0336
–  Fasten service door hinge to front door with M6 bolt -arrow-. Do not fully tighten bolt!
–  Install and align front door (adjust transitions, gaps and shut lines).
–  Gaps and shut lines → Rep. gr.00.
–  Tighten M6 bolt -arrow- and re-check door alignment, adjust where necessary.
  N57-0337
–  Tack weld service door hinge with four shielded-arc spot welds, recheck door alignment and adjust if necessary.
–  Fully weld in service door hinge and re-check door alignment.
–  Remove door, check weld seams and remove M6 bolt.
–  Weld hole in service door hinge.
–  Clean weld seams, remove residual deposits from grinding and priming, and apply primer (also on inner side of door).
–  Seal connection area of door hinge using adhesive sealant -D 511500 A2-.
–  Paint structure must be restored according to specifications in the → Paint workshop manual.
–  Finish assembling front door.
  N57-0338

Replacing A-pillar side hinge half > < Renewing front door