Volkswagen Passat B5: Trunk lid, (Sedan) (eng.)
55-11
Trunk lid, (Sedan)
Assembly overview
1 - Trunk lid/tailgate
Adjusting
Page 55-15
Gaps/shut lines
Repair Manual, Body Collision Repair,Repair
Group 00; Body gaps/shut lines; Body rear
2 - Trim
Removing and installing
Repair Manual, Body Interior, Repair Group 70;
Removing and installing trunk lid trim
3 - Adjustment buffer
Adjusting
Page 55-15
4 - Hexagon nuts
22 Nm
5 - Hinge
6 - Bolt
22 Nm
55-12
7 - Rubber buffer
8 - Gas-filled strut
Removing and installing
Releasing gas
Page 55-13
Page 55-14
9 - Lock plate
Adjusting - within oversized holes
Gaps/shut lines
Repair Manual, Body Collision Repair,Repair
Group 00; Body gaps/shut lines; Body rear
10 - Hexagon nut
7.2 Nm
11 - Cables/hoses
12 - Hinge cover
13 - Rubber buffer
55-13
Gas strut, removing
- Support trunk lid/tailgate.
- Lift locking clip -1- with a screwdriver and pull gas-filled strut off ballhead stud -3-.
Note:
If it is intended to re-use gas-filled strut, then do not lever out locking clip 1- completely from the ball socket otherwise clip will be damaged.
1 - Locking clip
2 - Gas strut
3 - Ball head pin (part of trunk lid/tailgate hinge)
55-14
Gas strut, releasing gas
- Clamp gas-filled strut in vice in area x
50 mm.
Warning!
Clamp only within this area otherwise danger of accident!
- Saw through cylinder of gas-filled strut within first third of cylinder's
overall length using piston rod end of cylinder as reference point.
Note:
Protective goggles must be worn during sawing process.
Cover area of saw cut with a cloth.
Dispose of oil and cloth via existing disposal channels.
55-15
Trunk lid, adjusting up to 10.00
Note:
The trunk lid is adjusted correctly, when the shut
lines are even all-round, and it does not project
too far in or out and all contours align when
closed.
Vehicle must be standing on its wheels when
performing adjustments.
1 - Threaded sleeve (with left-hand thread)
2 - Spacer web
3 - Spreader pins with dismantling slot
4 - Detent lugs for basic setting
5 - Recess for detent lugs
6 - Detent slide
7 - Clamping screw
8 - Rubber buffer
- Lever out spreader pin in dismantling slot with a narrow screwdriver
and take adjusting stop out of tailgate.
- Take off rubber buffer and unscrew clamping screw (hexagon socket 3
mm) up to the edge of the detent slot.
55-16
- Adjust threaded sleeve -1- (left-hand thread) to a clearance of a = 3
mm. check clearance, e.g. with hexagon socket head wrench -9-.
Reinstall rubber buffer.
Note:
When new, the adjusting stop should be set to a clearance of 3 mm. The
spacer web -2- rests against the threaded sleeve -1-.
- Pull out detent slide and press in again far enough until locking lugs -4engage in the recess -5-.
Clearance between housing and rubber buffer: b
- Insert adjusting stop, press in spreader pins.
- Close tailgate with slight pressure.
- Open tailgate again.
10 mm.
55-17
- Screw in clamping screw -7- about 20...25 mm.
- Check adjustment.
55-18
Trunk lid, adjusting from 10.00
Note:
The trunk lid is adjusted properly, when it has the
same size gaps all around in closed position and
if it does not excessively protrude in or out and
the contours are flush.
To be able to perform adjustment, the vehicle
must be standing on its wheels.
- Loosen locking screw (socket head 3 mm) until
the locking slider can be pulled out.
- Pull locking slider out of housing and adjust to dimension a = 12.5 mm.
Note:
- In new condition, the adjusting stop is already adjusted to 12.5 mm
distance.
55-19
- With slight pressure, close trunk lid from center,
while pulling on the handle.
- Open trunk lid again.
- The trunk lid is not adjusted with a pre-tension of
approx. 2 mm.
- Screw in locking screw -1- up to dimension a = 25 mm.
- Check adjustment.
55-20
Trunk lid lock, removing and installing up
to 10.00
1 - Lock cylinder carrier
The lock cylinder can only be removed in
conjunction with the carrier.
Removing and installing
Page 55-27 .
2 - Hexagon nut
7 Nm
3 - Handle trim
Removing
- Remove lock cylinder carrier
27 .
Page 55-
- Unscrew hexagon nuts - 2 - and take
outer hand grip off trunk lid.
4 - Handle
5 - Push-button
55-21
6 - Pop rivet nut
Pull in with pop rivet nut tool V.A.G 1765 A
7 - Base for registration plate
Only press on the hatched area
The replacement part has two foils. The
first foil covers the adhesive surface, the
second must be pulled off after
assembling.
8 - Lock
Removing
- Remove tailgate trim.
Repair Manual, Body Interior, Repair Group 70;
Removing and installing trunk lid trim
- Disconnect connector on lock.
- Unclip operating rod - 12 -, unscrew
hexagon nuts - 2 - and take lock out of
trunk lid.
55-22
9 - Relay lever
10 - Hexagon nut
7 Nm
11 - Central locking actuator
Removing
- Remove lock cylinder carrier
27 .
Page 55-
- Unbolt actuator and allow to hang.
12 - Operating rod
Press relay lever - 14 - against stop and
insert operating rod stress-free
13 - Connector sleeve
14 - Relay lever
55-23
Installing
- Engage securing clip again.
- Insert lock cylinder into carrier.
- Fit the complete carrier onto the outer grip and
the studs, and engage into the outer grip (a
clicking must be heard).
55-24
Trunk lid lock and lock cylinder carrier,
removing and installing from 10.00
1 - Carrier lock cylinder
Removing
- Disconnect harness connectors for
license plate light, power lock adjusting
motor and lock cylinder switch.
- Unclip bowden cable -5- at lock. Then
remove hex nuts -2-.
- Carrier lock cylinder can now be
removed from trunk lid.
Installing
Installation is the reverse order of removal.
55-25
2 - Hex nut
7 Nm
3 - License plate backing
Only press on hatched area
The replacement part has two foils. One
foil covers the adhesive surface, the
second foil must be removed after
installation.
4 - Internally threaded pop rivet
Pull in using VAG1765A prying pliers for
internally threaded pop rivets
5 - Bowden cable
6 - Hex nut
7 Nm
55-26
7 - Lock
Removing
- Remove trim for trunk lid
Repair Manual, Interior, Repair Group 70; Trunk
lid trim, removing and installing.
- Disconnect harness connector at lock.
- Unclip bowden cable -5-, remove hex
nuts -6- and remove lock from trunk lid.
8 - Reversing lever
9 - Motor to unlock trunk lid -V139Removing
- Carrier lock cylinder -1-, removing and
installing
Page 55-24 .
- Unbolt motor and unhook.
10 - Operating rod
11 - Reversing lever
55-27
Lock cylinder carrier, removing and
installing up to 10.00
Removing
- Remove trunk lid trim
Repair Manual, Body Interior, Repair Group
70; Removing and installing trunk lid trim
- Separate connectors -arrows-.
- Unclip operating rod -2- for trunk lid lock.
- Unscrew hexagon nuts -1-.
- Release securing clip -arrow- by turning anti-clockwise with a
screwdriver and hold.
- Pull lock cylinder carrier -1- off trunk lid and therewith off outer hand
grip.
- The lock cylinder can now be taken out of the carrier.
55-28
Lock cylinder housing, removing and
installing from 10.00
1 - Carrier lock cylinder
2 - Guide piece
3 - Guide pin
4 - Handle
5 - Seal
6 - Lock cylinder housing
Clipped into the lock cylinder carrier
7 - Motor to unlock rear lid -V139Removing
- Remove lock cylinder carrier -155-24 .
- Unbolt motor and unhook.
8 - Screw
Page
55-29
9 - Carrier plate
Bolted onto the lock cylinder carrier
10 - Conductor housing
Secured to carrier using circlip
11 - Trunk lid release switch -E165Soldered onto lock cylinder carrier
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