Volkswagen Passat B3: Front doors (eng.)

Volkswagen B3 Passat

Body Exterior

57 Body - Front Doors (Page GR-57)

Central door locking assembly (Sedan) assembly (Wagon) bi-pressure pump checking gas flap activator master activators rear door activators pump/module location troubleshooting multi-point connector, identification

Front door assembly assembly, w/pwr windows glass, removing/installing inner door opening mechanism, removing/installing inner seal, removing/installing lock, assembly lock, removing/installing lock, removing/installing with freeplay adjustment lock cylinder, installing microswitch, removing/installing removing/installing

Impact bar assembly

Outer window channel removing/installing

Power window control module location/terminal identification

Window regulator removing/installing removing/installing w/power windows


Body Exterior

Front door, assembly (Page 57-10-1)

1 - Hinge

bolted to door, inserted into A-pillar.

secured with grub screw

2 - Trim plate, inner/outer

pull off

3 - Window channel, outer

mounted to window frame, cannot be removed without destroying, removing/installing, see section 57-50

4 - Glass removing/installing, see section 57-40 mounting on window regulator, see section 57-40 mounting dimensions on window carrier, see section 57-40

5 - Door removing/installing, see section 57-20 elongated holes in hinge 1 are for adjustment

6 - Window slot seal, outer

mounted onto door body flange

7 - Window slot seal, inner



Body Exterior

Front door, assembly (Page 57-10-2)

8 - Window channel, inner

mounted into door body flange

9 - Guide rail, rear

10 - 7.0 Nm (5.2 ft lb)

11 - Window regulator removing/installing, see section 57-30 installing glass to regulator, see section 57-40

12 - Bearing sleeve with collar remove before regulator is removed replaces bearing sleeve 13 without collar

13 - Bearing sleeve without collar

install with seal 14, only 12 available as replacement

14 - Seal

for 13, if damaged, replace with 12

15 - Cover

for 16

16 - Door check

17 - 7.0 Nm (5.2 ft lb)

18 - Clip

19 - Lock nut -65 Nm(4.8 ft lb)

20 - Guide rail, front

removing, push downward and toward inside of door

21 - 55 Nm (42 ft lb)

22 - Door check, outer cover

self adhesive, mounted to A-pillar


Body Exterior

Front door, assembly: Power windows (Page 57-15-1)

1 - Hinge bolted to door, inserted into A-pillar secured with grub screw

2 - Trim plate, inner/outer

pull off

3 - Window channel, outer mounted to window frame cannot be removed without destroying removing/installing, section 57-50

4 - Glass removing/installing, see section 57-40 mounting on window regulator, see section 57-40 mounting dimensions on window carrier, see section 57-40

5 - Door removing/installing, see section 57-20 elongated holes in hinge 1 are for adjustment

6 - Window slot seal, outer


7 - Window slot seal, inner

8 - Window channel, inner


9 - Guide rail, rear

10 - Bolt - 7.0 Nm (62 in. lb)


Body Exterior

Front door, assembly: Power windows (Page 57-15-2)

11 - Window regulator removing/installing, see section 57-30 installing glass to regulator

12 - Window regulator motor

13 - Cover

14 - Door check

15 - Bolt - 7.0 Nm (62 in. lb)

16 - Clip

17 - Lock nut - 6.5 Nm (66 in. lb)

18 - Guide rail, front

removing, push downward and toward inside of door

19 - Bolt - 55 Nm (42 ft lb)

20 - Outer cover, door check

self adhesive mounted to A-pillar


Body Exterior

Door, removing/installing (Page 57-20-1)

Note

If vehicle equipped with central door locking and power windows, door trim panel must be removed, and electrical wiring going into door disconnected.

Removing remove nut 6, pull out pin A from door check remove grub screws (arrow) from hinges lift door up and out of hinge bracket

Installing

Reinstall in reverse order of removal, noting the following: clean pin A and nut threads with wire brush, and coat pin with locking compound

AMV 197 000 01 or equivalent torque nut 6

6.5 Nm (4.8 ft lb)


Body Exterior

Window regulator, removing/installing (Page 57-30-1)

Removing remove door trim panel disconnect wiring for central door locking, power operated windows, if applicable unbolt glass from regulator (arrows) push glass and secure fully upwards hold and secure in place with tape pull bearing sleeve 12 off regulator pivot lift regulator until retaining lugs are free, then remove regulator

Installing

Reinstall all components in reverse order of removal.


Body Exterior

Window regulator, removing/installing: Power windows (Page 57-35-1)

Removing remove door trim panel retaining screws remove door trim panel, see Repair Group 70 remove door handle cover and handle remove inner door release lever slide rearward in direction of arrow disconnect power mirror connector at control switch remove upper door trim panel and disconnect power window control switch remove power window control switch from door trim panel

CAUTION!

DO NOT damage the plastic moisture barrier. Water leaks will occur if damaged moisture barriers are installed.

Always replace damaged moisture barriers.

remove lower door panel retaining screws remove lower door panel disconnect speakers push retainer pins into door on door trim panel mounts remove mounts remove door release lever assembly from door by sliding rearward carefully remove door plastic moisture barrier reconnect power window switch switch ON ignition

lower window regulator until mounting bolts for glass are visible in holes 3 loosen bolts and remove raise regulator to top position and tape glass in place lower regulator 1/2 way disconnect power window switch


Body Exterior

Window regulator, removing/installing: Power windows (Page 57-35-2) remove regulator mounting bolts (arrows) remove window regulator and motor remove Allan head screw from back of stop disc 1 remove disc note position of stops on disc

remove motor mounting bolts (arrows) and take out motor

Installing

Reinstall all components in reverse order, noting the following: install window regulator motor onto window regulator install stop disc onto regulator, and secure with allen screw note position of stops on disc recover push pins from door trim panel mounts inside of door


Body Exterior

Window regulator, removing/installing: Power windows (Page 57-35-3) reinstall window regulator into door with mounting bolts (arrows) note position of retaining lugs torque mounting bolts 7.0 Nm (62 in. lb) reconnect power window motor install black plastic guide arm 1 onto rear guide rail 2 lower window regulator until window glass mounting holes are visible in large opening in bottom of door sheet metal remove tape securing glass, and lower glass onto regulator lightly tighten glass to regulator assembly fully raise window, then lower until bolts are visible in holes 3 tighten bolts

7.0 Nm (62 in. lb) lower glass with regulator until lower slide rail is visible in lower opening of door shell ensure glass is set into front guide rail ensure black plastic guide arm 1 is set onto rear guide rail 2 check front to rear movement of door glass must not exceed 5.0mm (approx. 13/64 in.)

Note

If front to rear movement of glass exceeds 5.0 mm (approx. 13/64 in.) the glass will not stay in front guide rail when raised.

Check for bent guide rails. The front guide rail may be replaced as necessary. The rear guide rail is part of the door shell, and can only be straightened.

align front and rear guide rails as necessary


Body Exterior

Window regulator, removing/installing: Power windows (Page 57-35-4)

Note

The lower mounting hole may have to be elongated to align the front window guide. The rear guide rail may need to be tapped rearward with a hammer or mallet.

Apply corrosion protection to elongated hole.

operate window in both directions at least 10 times to ensure correct operation disconnect power window control switch reinstall plastic moisture barrier wrinkle free reinstall all other door trim components in reverse order of removal


Body Exterior

Power window control module, location/terminal identification (Page 57-36-1)

Location

The power window control module is located beneath the rear bench seat.

Connector terminal identification

11 = T 8a/1

12 = T 8a/2

13 = T 8a/3

14 = T 8a/4

15 = T 8a/5

16 = T 8a/6

17 = T 8a/7

18 = T 8a/8

21 = T 8c/1

22 = T 8c/2

23 = T 8c/3

24 = T 8c/4

25 = T 8c/5

26 = T 8c/6

27 = T 8c/7

28 = T 8c/8

31 = T 8b/1

32 = T 8b/2

33 = T 8b/3

34 = T 8b/4

35 = T 8b/5

36 = T 8b/6

37 = T 8b/7

38 = T 8b/8

Connector colors

T 8a - Brown

T 8b - White

T 8c - Black

Note

See wiring diagram for wire routing to connectors T 8a, T 8b and T 8c. Always refer to appropriate wiring diagram when performing any electrical tests or repairs.


Body Exterior

Door glass, removing/installing (Page 57-40-1)

Removing remove door trim panel pull off inner door window slot seal fully lower windows and secure in lowest position unbolt glass from regulator tilt and lift glass out of door as shown

Installing

Reinstall all components in reverse order of removal, noting the following: if glass was removed from carrier 1, remount as shown

a = 303 mm (approximately 11.8 in.)

install guide arm rail 1 to guide rail 2 bolt glass to regulator do not fully tighten fully raise window, then lower until bolts are visible in holes 3 fully tighten bolts

7.0 Nm (5.2 ft lb)


Body Exterior

Outer window channel, removing/installing (Page 57-50-1)

Removing remove inner/outer trim plates pull off outer window slot seal pull off inner window slot seal starting at upper corner, carefully snap (pry) off outer window channel from door flange, as shown

Installing tilt channel into window slot at rear starting at upper corner, press channel downward onto door flange retaining lip (arrow B) must engage flange fully reinstall all other components


Body Exterior

Impact bar, assembly (Page 57-60-1)

Note

Impact bar is located under the protective molding A.

1 - 25 Nm (18 ft lb)

2 - Washer

3 - Grommet

4 - Impact bar


Body Exterior

Door lock, assembly (Page 57-70-1)

1 - Support

rotate 90 (1/4 turn) to remove

2 - Door handle

removing/installing,see section 57-100 in vehicles with central door locking, door trim panel must be removed and connector 6 pulled off

Reduce free play on door handle by turning adjuster 7

3 - Lock cylinder

remove only with key when reinstalling, lubricate with grease G 000 400 or equivalent

4 - Gasket

5 - Clamp

6 - Connector, central door locking

7 - Adjuster

Adjustable, reduces free play at door handle between adjuster and lock operating lever

19 = 0.1 - 1.0mm (approx. 0.004 - 0.039 in)

adjusting: remove door handle or adjust from inside door if vehicle equipped with central door locking

8 - Screw w/washer

7.0 Nm (5.2 ft lb)

9 - Lock rod


Body Exterior

Door lock, assembly (Page 57-70-2)

10 - Lock knob

screwed on 9

11 - Locking lever

12 - Microswitch

for automatic shoulder belt system only

13 - Door lock removing: door glass must be fully raised (closed) if necessary, adjust free play between lock and door handle

14 - Striker bolt -50 Nm (37 ft lb)

15 - Washer

collar faces away from B-pillar

16 - Plastic washer

17 - 20 Nm (15 ft lb)

18 - Seal

must match door lock

19 - Operating lever

insert into inner door opening mechanism from underneath

20 - Circlip

21 - Clip

22 - Swivel bushing

23 - Spring

24 - Inner door opening mechanism

removing, see section 57-120


Body Exterior

Door lock, removing/installing (Page 57-75-1)

Door lock with freeplay adjustment as of Jan. 1992

1. Door handle

2. Door lock with freeplay adjustment

3. Bolt

20 Nm (15 ft lb)

4. Cap

5. Nut freeplay adjustment

Removing

- unclip cap -4-

- remove bolt -3-

- pull away door lock -2- slightly and lock operating lever with 3mm mandrel

- pull out door lock and unhook pull rod from inner lock mechanism


Body Exterior


- loosen nut -3- with 5.5mm wrench release lever will give way right side = left hand thread left side = right hand thread

1 Assembly position

- install door lock freeplay adjustment actuated between release lever and actuating lever

2 Installed position

- tighten nut -3-, use torque wrench VAG 1783 and insert VAG 1784

24 Nm (2 in.lb)

- make adjustment after every removal of door handle or door lock

- check proper function


Body Exterior

Door handle, assembly (Page 57-80-1)

1 - Lock cylinder remove with key inserted do not lose spring 2, ball 3 on passenger handle, ball may be located between microswitch 6 and handle 5 lubricate lock cylinder with grease G 000 400 or equivalent

2 - Spring

do not lose when removing lock cylinder 1

3 - Ball

do not lose when removing lock cylinder 1 located between microswitch 6 and handle 5 on passenger side

4 - Sealing ring

5 - Door handle

with electrical connection for central door locking disconnect before removing

6 - Microswitch

cannot be removed

7 - Mounting hole

for ball 3, spring 2

8 - Bushing

adjusts free play in door handle. Free play between bushing and lever from lock

0.1-1.0 mm (0.004-0.039 in.)


Body Exterior

Door handle, assembly (Page 57-80-2)

9 - Circlip

10 - Swivel bushing

install with spring 11

11 - Spring

12 - Seal


Body Exterior


Removing remove door trim panel partially pull off plastic moisture barrier.

disconnect wire to lock on vehicles with automatic shoulder belt system insert 3.0 mm (1/8 in.) punch as shown and lock operating lever (arrow) open door from inside remove screws A

Installing

Reinstall all components in reverse order noting the following: check tolerance (free play of door handle) between adjuster and door lock operating lever, adjust if necessary

0.1-1.0 mm (0.004-0.039 in.) screws A 20 Nm (15 ft lb)


Body Exterior

Door handle, removing/installing: Left side - all VIN numbers, Right side - up to

Vin NE 190 000 (Page 57-100-1)

Removing

Note on vehicles with central door locking, remove door trim panel, pull back plastic moisture barrier and disconnect wire to handle.

remove screw A push door handle in direction of arrow and pivot out of door

Installing

Reinstall all components in reverse order, noting the following: clip and route wire to lock on vehicles with central door locking so not to interfere with lock operation check washer 2 and clip 3 for damage check tolerance (free play of door handle) between adjuster and operating lever. If necessary adjust by turning adjuster

0.1-1.0 mm (0.004-0.039 in.) screw A, 7.0 Nm (5.2 ft lb)


Body Exterior

Right side door handle, removing/installing: From VIN NE 190 000 (Page 57-105-

1)

Removing

Note

Mounting screw 1 on right side door handle now has left hand threads.

On vehicles with central door locking, remove door trim panel, pull back plastic moisture barrier and disconnect wire to handle.

remove mounting screw 1 left hand threads push door handle in direction of arrow A and pivot out of door

Installing

Reinstall all components in reverse order, noting the following: clip and route wire to lock on vehicles with central door locking so not to interfere with lock operation check washer 2 and clip 3 for damage check tolerance (free play of door handle) between adjuster and operating lever. If necessary adjust by turning adjuster

0.1-1.0 mm (0.004-0.039 in.) tighten screw 1

7.0 Nm (5.2 ft lb)


Body Exterior

Lock cylinder, installing (Page 57-110-1) install gasket on lock cylinder as shown slightly pull back gasket (arrow) at area of microswitch slightly pull outside door handle and hold as if opening door insert lock cylinder sufficiently until hole in cylinder and housing are covered.

coat ball with grease and place on spring push ball with spring into lock with tool 1, as shown tool is small diameter tube. 2.5 mm (3/32 in.) by approximately 50 mm (2.0 in) long turn lock cylinder to stop, then an additional 90

check that ball is visible in gap between lock cylinder housing and lock cylinder

(arrow) check that lock cylinder rotates approximately 70 to either side install circlip onto end of lock cylinder position swivel bushing with spring push ends of spring back spring should touch tab protruding from lock cylinder housing swivel bushing is correctly fitted if lock ring groove is not covered install lock ring check lock cylinder for proper function spring must always return lock cylinder to center position


Body Exterior

Inner door opening mechanism, removing/installing (Page 57-120-1)

Removing insert screwdriver as shown, and pry out securing clip from hole in door panel push out inner door opening mechanism in direction of arrow

Installing

Reinstall all components in reverse order of removal.


Body Exterior

Door microswitch, removing/installing (Page 57-130-1)

Removing pry microswitch out of tabs (arrows)

Installing clip into tabs route wires through clip A


Body Exterior

Door inner seal, removing/installing (Page 57-140-1)

Removing remove inner trim remove seal

Installing

Reinstall all components in reverse order of removal, noting the following: door inner seal starts at point 2

a = 520 20 mm (approximately 20 3.0 in.) from front lower corner of door opening


Body Exterior

Central door locking, assembly: Sedan (Page 57-150-1)

1 - Bi-pressure pump

located under trim, left side trunk installing, section 57-170

2 - T-connector

located by Bi-pressure pump

3 - Activator, rear doors

removing/installing, section 57-200

4 - T-connector

located at base of B-pillar, covered by door sill

5 - Master activator, front doors


6 - Activator, gas flap

loosen truck trim to remove, removing/installing section 57-180

7 - Activator, rear lid

removing, open hinge on activator, unhook connecting rod

8 - T-connector

located at wheel house/seatback under trunk carpet


Body Exterior

Central door locking, assembly: Wagon (Page 57-160-1)

1 - Activator, gas flap located in right rear, remove right side loading area trim, and loosen right front loading area trim removing/installing, section 57-180

2 - Foam tubing

3 - T-connector

located near fuel tank lid activator

4 - Activator, tailgate

remove tailgate trim for access

5 - Grommet

6 - Activator, rear doors


7 - Master activator, front doors


8 - T-connector

located at base of B-pillar/side member covered by door sill trim

9 - Bi-pressure pump

located in depression at right rear floor

10 - T-connector

located behind right wheel house

11 - T-connector

located between wheel house and seatback, covered by front loading area trim


Body Exterior

Bi-pressure pump, installing (Page 57-170-1) insert pressure line install multi-point connector to bi-pressure pump ensure terminal 1 (4-pin) is secured by clip do not pinch sunroof drain hose 2 when reinstalling bi-pressure pump reinstall sound deadener around bi-pressure pump reinstall trunk trim


Body Exterior

Gas flap activator, removing/installing (Page 57-180-1)

Removing loosen screws unhook activator with lock rod from lock guide 3 pull off pressure/vacuum hose A

Installing

Reinstall in reverse order, noting the following: check gas flap activator for proper function before reinstalling luggage compartment trim


Body Exterior

Master activators, removing/installing (Page 57-190-1)

Removing remove door panel trim partially remove plastic moisture barrier disconnect inner door opening mechanism and locking rod pull pressure/vacuum hose out of retaining clips open hinge 4, and unhook lock rod loosen screws, remove activator from top pull pressure/vacuum hose out of activator

Installing

Note

For lock rod assembly, activator and door lock must be in locked (closed) position.

reinstall pressure/vacuum hose reinsert screws, install and secure activator reinstall inner door opening mechanism and locking rod lock washer 5 must be locked

push in lock rod and close hinge 4

CAUTION!

Do not pull lock rod downward when pushing in.

Note

When locking, hinge 4 must turn lock washer 5 and unlock.

check plastic moisture barrier for damage or wrinkles replace or repair as necessary additional two-sided tape, Part No. AKL 440 025 or equivalent may be applied reinstall door trim check central locking for proper function


Body Exterior

Rear door activators, removing/installing (Page 57-200-1)

Removing remove rear door trim partially remove plastic moisture barrier unhook line from clip 6 open hinge 4, and unhook lock rod loosen screws and remove activator from below pull pressure/vacuum hose off activator

Installing

Note:

For lock rod assembly, activator and door lock must be in locked (closed) position.

reinstall pressure/vacuum hose reinsert screws, install and secure activator reinstall inner door opening mechanism and locking rod lock washer 5 must be locked (arrows) rehook lines in clip 6

push in lock rod and close hinge 4

CAUTION!

Do not pull lock rod downward when pushing in.

Note

When locking, hinge 4 must turn lock washer 5 and unlock.

check plastic moisture barrier for damage or wrinkles replace or repair as necessary additional two-sided tape, Part No. AKL 440 025 or equivalent may be applied reinstall door trim check central locking for proper function


Body Exterior

Central door locking, checking (Page 57-210-1)

Note

All locks must close within approximately 2 seconds.

If the bi-pressure pump runs longer than 5 seconds, either the linkage or the activator is not correctly adjusted or the system has leaks.

The shut-off point in the activator is not attained if the linkage is not adjusted correctly - bipressure pump "pulses." After approximately 35 seconds the control unit must shut off the bi-pressure pump.

Note

Central locking of all activators is possible through both driver and front passenger door locks.


Body Exterior

Central locking system, troubleshooting (Page 57-220-1)

Note

Always refer to appropriate wiring diagram.

Tools required

Multimeter Fluke 83

Connector Test Kit VW 1594

CAUTION!

DO NOT damage, enlarge or bend connector terminals or cavities by forcing probes into them when performing electrical checks. Use Connector Test Kit VW 1594 to make the necessary electrical connections.

Test conditions battery OK fuse S 16 OK fuse S 21 OK

Note

If one or more locks do not open or close, check if the vacuum pump remains on longer than 5 seconds, then pumps again after a short time. If so, there is a leak in the vacuum system which must be eliminated prior to troubleshooting.


Body Exterior



Body Exterior



Body Exterior

Central locking system pump and control module, location/terminal identification (Page 57-230-1)

Location

Vehicle/model

Location of central locking system pump and control module (V 69)

Passat sedan luggage compartment, left side, rear

Passat wagon luggage compartment, right side, next to spare tire molding

Connector terminal identification

1 = T 12/1

2 = T 12/2

3 = T 12/3

4 = T 12/4

5 = T 12/5

6 = T 12/6

7 = T 12/7

8 = T 12/8

9 = T 12/9

10 = T 12/10

11 = T 12/11

12 = T 12/12

Connector color

T 12 - transparent

Note

See wiring diagram for wire routing to connector T 12. Always refer to appropriate wiring diagram when performing any electrical tests or repairs.

Volkswagen Passat B3: Front doors (eng.)

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