Transcript
58-1
Rear door Tools Special tools and equipment T 10011 Socket 3320/2 Bit insert for 3320 3410 Socket T 10034 Assembly tool
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Rear door, assembly overview Note: The hinge bolts must always be replaced if loosened. 1 - Door Removing and installing
Page 58-7
2 - Door handle with base Removing and installing
Page 58-11
3 - Housing Removing Removing lock cylinder housing on page 57-11 4 - Bolt 20 Nm (15 ft lb) 5 - Cover cap 6 - Locking button Removing and installing 7 - Locking rod
Page 57-23
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8 - Bell crank 9 - Locking rod 10 - Bolt 20 Nm (15 ft lb) 11 - Lock plate 12 - Door lock Removing and installing
Page 58-14
13 - Bowden cable 14 - Interior release handle 15 - Multi-point socket head bolt M8 x 28 20 Nm (15 ft lb) + 1/4 turn further (90 ) Always replace bolt after loosening
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16 - Multi-point socket head bolt M8 x 28 Only remove this bolt from hinge to remove door 20 Nm (15 ft lb) + 1/4 turn further (90 ) Always replace after loosening 17 - Door hinge with check Hinge is divided 18 - Multi-point socket head bolt M8 x 28 Install from inside vehicle Remove B pillar lower trim Repair Manual, Body Interior, Repair Group 70; Pillars and side trims 20 Nm (15 ft lb) + 1/4 turn further (90 ) Always replace bolt after loosening
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19 - Multi-point socket head bolt M8 x 28 20 Nm (15 ft lb) + 1/4 turn further (90 ) Always replace bolt after loosening 20 - Multi-point socket head bolt M8 x 28 20 Nm (15 ft lb) + 1/4 turn further (90 ) Always replace bolt after loosening 21 - Cover cap 22 - Bolt 13 Nm (10 ft lb) 23 - Door hinge Hinge is divided
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24 - Multi-point socket head bolt M8 x 22 Install from inside vehicle Remove B-pillar lower trim Repair Manual, Body Interior, Repair Group 70 20 Nm (15 ft lb) + 1/4 turn further (90 ) Always replace bolt after loosening 25 - Multi-point socket head bolt M8 x 28 20 Nm (15 ft lb) + 1/4 turn further (90 ) Always replace bolt after loosening
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Door, removing and installing - Remove B-pillar upper and lower trim.
Repair Manual, Body Interior - Disconnect multi-pin wiring connector under rubber boot -3- on B-pillar. - Pry off cover cap -2- with a screwdriver. - Remove bolt -1- from upper hinge. Tightening torque = 13 Nm (10 ft lb). - Remove lower bolt -4- from hinge. Tightening torque = 20 Nm (15 ft lb) + 1/4 turn (90 ) further Note: Always replace the lower hinge bolt -4-. - Lift door upward out of hinge brackets.
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Door, adjusting To adjust the door the hinges on the pillar must be loosened. Other methods, such as raising the door upward, have no effect. Excess pressure in one direction will again cause the door to sag. Use the door adjustment wrench 3320 with bit insert 3320/2 to adjust the door. When loosening the door hinge on the B-pillar from the interior, socket 3410 can be used. The B-pillar lower trim must be removed before loosening the hinge.
Repair Manual, Body Interior, Repair Group 70
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Door handle and door lock, assembly overview 1 - Door lock Door lock can only be removed in conjunction with assembly carrier. Removing and installing
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2 - Cable For lock release 3 - Retaining bracket Bolted and riveted to door lock Not supplied with door lock 4 - Handle bracket Removing; Door handle, lock cylinder housing and assembly carrier are removed - Remove screw - 5 -, slide bracket slightly to rear and remove from door.
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5 - Screw 6 - Door handle with base Removing and installing
Page 58-11
7 - Cover cap 8 - Lock cylinder housing Removing
Page 57-11
9 - Backing 10 - Multi-point socket head bolt Use socket insert T 10011 Loosening releases lock cylinder housing - 8 -, which can then be removed from bracket - 4 Bolt must not be threaded in without lock cylinder housing installed or locking ring may fall into door.
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Door handle, removing and installing Removing - Pull off door seal -1- in area of door handle. - Pull door handle -2- in direction of arrow and hold. Unscrew bolt -4- onto stop using socket insert T 10011. This releases the lock cylinder housing. Note: Unscrewing the bolt too far may cause the locking ring to release from the handle bracket and fall into the door. - Pull out housing -3- at right angles to door, from door handle backing. - Unclip clip -1- from door handle. - Swing door handle out of door.
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- Place assembly tool T 10034 through hole of door sheet metal. - Using a flashlight to view door interior, hook assembly tool in spring -1- (arrow -A-). - Hang spring up into door lock by pulling assembly tool (arrow -3-). - Check function of door handle.
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Installing - 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. - Check door handle function. An incorrectly installed and adjusted bowden cable cannot open door. To remove housing, see removing lock cylinder housing
Page 57-11 .
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Door lock, removing and installing The window regulators, the door lock and the loudspeaker are secured to the door 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 is released from window regulator. This is accomplished by lowering the door window to the height of the assembly holes in the assembly carrier and removing the spreader pins. If the power windows cannot be lowered then the cause must be determined. Check the comfort locking system Diagnostic Trouble Code (DTC) memory (address word 46) with the VAG 1551 scan tool.
Repair Manual, Body On Board Diagnostic (OBD), Repair Group 01. If an electrical malfunction is present it must be corrected first. If it is determined that a window motor is the cause of the malfunction, proceed as
described on
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Removing - Remove rear door trim.
Repair Manual, Body Interior, Repair Group 70
- Remove housing, see removing lock cylinder housing Page 57-11 . - Pry out cover cap -1-. - Lower door window until spreader pin -2- and spreader plug -3- are accessible in cut-out in window regulator. Note: If the sequence cannot be carried out because of a malfunction in the window motor, remove the motor to the slide window down. - Thread a 5 mm bolt (approx. 70 mm long) into the spreader pin -2- and pull out from spreader plug -3-. - Thread an 8 mm bolt (approx. 80 mm long) into spreader plug -3-. Note:
Use only light pressure when threading the bolt into the plug or the plug may fall into the door.
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- Pull spreader plug out from window guide and out of door window while pressing window regulator bowden cable -2- to side with a screwdriver. - Pull seal -1- off quarter window frame to window shaft seal -2-. - Pry out cover cap -3-. - Remove bolt which is visible through hole in panel.
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- Lift locking tab -2- with screwdriver -1- and take filler piece -3- off window frame in an upward direction.
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- Grip window shaft inner seal -1- with pliers -2-. Move pliers in direction of arrow while lifting window shaft seal -1- out of door flange using a light rotational movement. Note: The process may be eased using a wedge -3- to assist the pliers.
- Slide door window -1- upward and pull inward (arrow) out of door.
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- Pull window guide -1- off in upper area and remove screw -2- on quarter window frame. Note: The screw -2- will be gradually discontinued. The quarter window frame will then be clipped into the top of the door. The remainder of the procedure remains identical.
- Remove hex bolt -1-. - Pull quarter window frame -2- off quarter window seal -3- and pull downward off upper window guide.
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- Pull quarter window frame -1- upward out of door.
- Pull boot -1- off at B-pillar. - Disconnect wiring connector -2-.
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- Remove bolts (arrows). - Remove bolts -1- (for lock).
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- Pull top of assembly carrier off door, lift carrier and remove from door toward hinges (arrow). - Release two wiring clips from reinforcing plate in door and pull wiring out of boot.
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Installing - Pull operating lever -1- in direction of arrow. - Tension spring -2- on door lock in direction of arrow with a screwdriver and hook notch on locking lever into spring. Note: Hooking the operating lever locks the mechanism. The incorrect attachment of the bowden cable later is thus prevented.
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- Guide electrical wiring through boot into door and secure clips in door panel. - Insert assembly carrier in door. - Install all bolts. Tighten bolts marked -1- and -2- in sequence. Tightening torque: 8 Nm (70 in. lb) Note: The remaining bolts can be tightened in any sequence. - Install door window,
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Remaining installation is in reverse order of removal. - Perform functional check of door lock.
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Door window, assembling to window regulator - Insert spreader plug -2- and spreader pin -1- into window. - Set spreader plug projection on each side of window. - Guide window into door. - Insert door window -3- into window regulator lift rail guide slot -4-. - Lightly tap top of window, so that window locates in lift rail (arrow).
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Door seals, assembly overview 1 - Door inner seal Start at upper radius of door cut-out when installing seal 2 - Door inner seal, 4-door 3 - Clip Inserted in door seal 4 - Door outer seal, 4-door 5 - Clip Inserted into door seal Note: The trim must be removed to remove the door seals.
