Volkswagen Passat B5: Front door (eng.)

Volkswagen Passat B5: Front door (eng.)
57-1
Front door
Tools
Special tools, workshop equipment, testers,
measuring instruments and auxiliary items
required
T 10011 Socket insert
T 10072 Socket wrench
T10118 Assembly tool
3320/2 Box spanner
3320/3 Box spanner
3410 Socket insert
57-2
Assembly overview
Note:
The hinge bolts must always be replaced if
loosened.
The dash panel must be removed to remove and
adjust the upper door hinges.
1 - Door
Removing and installing
Page 57-7
2 - Door handle with base
Removing and installing
Page 57-15
3 - Lock cylinder housing
Removing
Page 57-13
4 - Cover cap
5 - Screw
20 Nm
6 - Locking button
Removing and installing
Page 57-29
57-3
7 - Locking rod
8 - Bellows
9 - Screw
20 Nm
10 - Lock plate
11 - Door lock
Removing and installing
Page 57-18
12 - Bowden cable
13 - Interior release handle
Removing and installing
Page 57-26
14 - Multi-point socket head bolt
M8 x 28
20 Nm + 1/4 turn further (90 )
Always replace bolt after loosening
57-4
15 - Multi-point socket head bolt
Only remove this bolt from hinge to remove
door
M8 x 28
20 Nm + 1/4 turn further (90 )
Always replace bolt after loosening
16 - Door hinge with arrester
Hinge is split
17 - Multi-point socket head bolt
M8 x 28
Install from inside vehicle
Remove A pillar lower trim
Repair Manual, Body Interior, Repair Group 70;
Pillars and side trims
20 Nm + 1/4 turn further (90 )
Always replace bolt after loosening
57-5
18 - Multi-point socket head bolt
M8 x 28
20 Nm + 1/4 turn further (90 )
Always replace bolt after loosening
19 - Multi-point socket head bolt
M8 x 28
20 Nm + 1/4 turn further (90 )
Always replace bolt after loosening
20 - Cover cap
21 - Grub screw
23 Nm
22 - Door hinge
Hinge is split
57-6
23 - Multi-point socket head bolt
M8 x 22
Install from inside vehicle
To loosen or tighten the bolt, remove and
install dash panel
Repair Manual, Body Interior, Repair Group 70;
Dash panel
20 Nm + 1/4 turn further (90 )
Always replace bolt after loosening
24 - Multi-point socket head bolt
M8 x 28
20 Nm + 1/4 turn further (90 )
Always replace bolt after loosening
57-7
Door, removing and installing
Note:
Various screws are used to secure the door hinge.
There are two box spanners for this, bit 3320/2
(Emden production only) as well as 3320/3.
- Remove A pillar lower trim -5Repair Manual, Body Interior, Repair Group 70;
Pillars and side panel trims; Removing A pillar
lower trim
- Pull bellows -3- off A pillar. Guide electrical
cables out of pillar through hole -arrow-.
- Lever out cap -1- and remove grub screw -2from upper hinge.
Tightening torque: 23 Nm
57-8
- Remove lower bolt -4- from hinge.
Tightening torque: 20 Nm + 1/4 turn further
(90 ).
Note:
Always replace this bolt.
- Lift door out of door brackets upwards.
57-9
Door, adjusting
To ensure a correct door adjustment the door
hinges on the pillar must be loosened. Other
measures such as raising the door upwards have
no effect. Over pressuring thereafter will again
cause the door to sack.
Use door adjustment wrench 3320 with box
spanner 3320/2 (Emden production only) or box
spanner 3320/3.
If there is a requirement to loosen the door hinge
on the upper A-pillar from the interior, socket
3410 can be used. The dash panel must be
removed for this.
Repair Manual, Body Interior, Repair Group
70; Dash panel; Removing and installing dash
panel.
57-10
Door handle and door lock, assembly
overview
1 - Door lock
Door lock can only be removed in
conjunction with the subframe
Removing and installing
Page 57-18
Cover - 4 - was introduced as a running
change in production for the lock. It is
clipped onto the lock and must be reinstalled or retrofitted when replacing the
door lock.
2 - Cable
Lock release
3 - Angle bracket
Bolted and riveted to door lock
Does not belong to door lock delivery
casing
57-11
4 - Cover
Does not belong to door lock delivery
casing
Must be re-installed or retrofitted when
replacing door lock
Retrofit for all vehicles
09.99
5 - Mounting bracket
Removing
Door handle, lock cylinder housing and
subframe have been removed
- Remove Phillips-head screw - 6 -, slide
mounting bracket slightly to rear and
remove from door.
6 - Phillips-head screw
7 - Door handle with backing plate
Removing and installing
Page 57-15
57-12
8 - Concealment cap
9 - Lock cylinder housing
Removing
Page 57-13
Lock cylinder is not available as an
individual replacement part
10 - Base plate
11 - Socket-head bolt
T 10011 Socket insert
T 10072 Socket wrench
By loosening this bolt, locking mechanism
for lock cylinder housing - 9 - is disengaged
and may be removed from mounting
bracket - 5 Bolt - 11 - must not be threaded in without
lock cylinder housing installed. Lock
mechanism ring may fall into door
57-13
Lock cylinder housing, removing and
installing
Removing
- Lever out cover cap -3-.
- Pull door handle -1- and hold. Unscrew screw -3- onto stop with socket
insert T 10011 (socket wrench T10072 has been introduced gradually).
This releases the lock cylinder housing.
Note:
Unscrewing the bolt too far may result in the locking ring releasing from
the mounting bracket and falling into the door.
- Pull lock cylinder housing -2- out of door handle mounting bracket at
right angles.
57-14
Installing
- Fit lock cylinder housing in door handle
mounting bracket at right angles.
- Fit screw in mounting bracket and tighten with
socket wrench.
The door handle locates in the lock cylinder
housing with an audible click.
Note:
Press door handle and lock cylinder housing
against door panel when assembling.
- Then perform remaining installation in reverse
order.
Then perform a functional check always as
an incorrectly fitted and adjusted Bowden
cable cannot open the door.
57-15
Door handle, removing and installing
Removing and installing lock cylinder housing
Page 57-13 .
Removing
- Unclip clip -1- from door handle.
- Swing door handle out of door.
Installing for vehicles up to Vehicle Identification Number (VIN) 3B
XE 059 999 and to 3B XP 077 999
- Swing door handle into door.
- Pull clip -1- into panel cut out and engage in door handle -2-.
Note:
When assembling clip, do not pull lock operating lever -3- and press door
handle -2- onto door panel.
Installing lock cylinder housing
Page 57-13
Then perform functional check.
57-16
Installing for vehicles from Vehicle
Identification Number (VIN) 3B XE 060 000, and
3B XP 075 000
- Guide assembly tool T10118 into door through
opening in the inner door plate.
- Illuminate the inner part of door using a flashlight
for better view.
- Hook assembly tool into spring (arrow -A-).
- Engage spring into door lock by pulling assembly
tool (arrow -B-).
Activation lever is now locked.
57-17
- Swing door handle into door.
- Pull clip -1- into panel cut out and engage in door handle -2-.
Note:
Press door handle -2- against door panel when assembling.
Installing lock cylinder housing
Page 57-13
Then always perform a functional check with the door open as an
incorrectly fitted and adjusted Bowden cable cannot open the door.
57-18
Door lock, removing and installing
The window lifters, the door lock and the
loudspeaker are secured to the assembly
carrier.
The door lock can only be removed in
conjunction with the assembly carrier.
The assembly carrier can only be removed when
the door window clamping brackets of the
window lifter are unscrewed. To do this lower
door window to the height of the assembly holes
in assembly carrier and loosen clamping
brackets.
If electrical windows cannot be lowered then the
cause of the fault must be determined first.
To do this interrogate convenience locking
systems fault memory (address word 46) with
fault reader V.A.G 1551
Repair Manual, Body On Board Diagnostic
(OBD), Repair Group 01; Convenience system;
Interrogating fault memory.
If a fault is present then proceed as described on
pages Page 57-20 and Page 57-21 .
57-19
Removing
All vehicles
- Removing front door trim
Repair Manual, Body Interior, Repair Group
70; Removing and installing door trim
- Removing lock cylinder housing
13 .
- Unclip clip -1- from door handle.
- Lever out cover cap -1-.
Page 57-
57-20
Vehicles with electrically operated windows
Note:
If motors fail, proceed as follows.
- Unscrew bolts -1- (Qty. 4).
- Pull housing -2- off window motor.
Bosch electric window lifter motor
- Pull armature -1- off window motor -arrow-.
- The door window can now be pushed down to the height of the
assembly holes in the assembly carrier.
Note:
The motor must not be reused.
57-21
Siemens electric window lifter motor
- Unscrew bolts -1- (Qty. 4).
- Pull housing -2- off window motor.
Note:
The motor must not be reused.
- The door window can be lowered down to the height of the assembly
holes by turning the armature -1-.
57-22
All vehicles
- Lower door window until door window securing bolts are accessible.
- Loosen bolts -2- and press clamps apart.
- Push window upward and secure in position (e.g. with adhesive tape).
- Disconnect all connections -arrows-.
57-23
- Lever out cover cap -3-.
- Unscrew bolts -2- Tightening torque: 20 Nm.
- Unscrew bolts -arrows-. Pull top of assembly carrier off door, lift and
take out of door towards hinges.
- Turn assembly carrier and pull connector off door lock.
- Then unclip clips for electrical cables on back of assembly carrier.
57-24
- Drive out clips -1- with a drift.
- Unclip cable -2- from clip -1-.
- Lever door lock with retaining bracket off assembly carrier using a
screwdriver -3-.
Note:
The retaining bracket is not part of the items supplied with the door lock.
Secured to door lock with a bolt and a pop rivet.
57-25
- Unclip securing rod -1-. To do this turn door lock in direction of arrow.
- Unclip cable -2-.
- Turn cable nipple through 90
and take out from eye.
Installing
Notes:
When replacing door lock, make sure that the cover (Item - 4 -,
Page 57-11 ) is re-installed or retrofitted on door lock.
Retrofit cover for all vehicles
09.99.
- Insert assembly carrier in door.
- Fit bolts and tighten in the prescribed sequence. Tightening torque: 8
Nm.
- Loosen clamps, press door window -1- into the window guides -arrowand tighten clamp with bolts -2- (10 Nm).
Install remainder in reverse order.
Then perform functional check.
57-26
Inner release handle, removing
- Removing front door trim
Repair Manual, Body Interior, Repair Group
70; Removing and installing door trim
- Remove cross head screw -1-.
- Unclip switch -2- for electric windows.
- Unclip door inner release -arrows- and take out from door trim.
57-27
Door seals
Door seals are fitted in series production with a
sealant, they are placed on the door flange and
then rolled on.
Note:
If they are removed the sealant will spread on the
inside of the seal and the flanks will be bent out
slightly. If the seal is then refitted there is no
guarantee that it will fit tightly and seal.
Therefore each seal which is removed
completely should be replaced by a so called
"hammer blow" seal.
When seals have been partially removed
squeeze the flanks together before refitting.
57-28
Door inner seal, removing and installing
- Pull door inner seal off body flange.
- When installing the door inner seal, start at upper radius of the door
cut-out -1-.
57-29
Locking knob for locking rod, removing
and installing
The description for removing and installing the
locking knob must be adhered to.
Not observing the sequence, may unscrew the
locking rods in the front door locks and the relays
in the rear doors or damage the mountings.
57-30
Removing
Front right and rear left doors
- Release locking knob by turning 180
anti-clockwise.
- Take locking knob off upwards.
Installing
Front right and rear left doors
- Fit locking knob onto locking rod with mark -small dot on top- towards
vehicle interior.
- Press locking knob onto locking rod until the fluted section is flush with
the height of the door trim.
- Then turn the locking knob 180
anti-clockwise.
Locking knob in "locked" condition can project approx. 0...2 mm above
door trim.
57-31
Removing
Front left and rear right doors
- Release locking knob by turning 180
clockwise.
- Take locking knob off upwards.
Installing
Front left and rear right doors
- Fit locking knob onto locking rod with mark -small dot on top- towards
vehicle interior.
- Press locking knob onto locking rod until the fluted section is flush with
the height of the door trim.
- Then turn the locking knob 180
clockwise.
Locking knob in "locked" condition can project approx. 0...2 mm above
door trim.
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