VW Passat & Audi A4 1990-2000

Door Locks

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REMOVAL & INSTALLATION
A4 & Passat
FRONT DOOR LOCK ASSEMBLY

Window regulators, door lock and radio speaker 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 window clamping brackets of the window regulator are unscrewed.

To do this, lower the door window to the height of assembly holes in the assembly carrier and loosen the clamping brackets.


NOTE
If the electrical windows cannot be lowered, then the cause of the malfunction must be determined and repaired first.


NOTE
When replacing the door lock, ensure that the cover is reinstalled or retrofitted on the door lock.



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Fig. Removing the door handle: clip (1), handle (2), clip (3)

  1. Remove the front door trim.
  2.  
  3. Remove the lock cylinder housing.
  4.  
  5. Unclip the clip (1) from the door handle.
  6.  
  7. Pry off the cover cap.
  8.  
  9. Lower the door window until the bolts are accessible. Loosen the bolts and press the clamps apart. Move the window up and secure in position.
  10.  
  11. Disconnect all of the appropriate wiring connectors.
  12.  
  13. Pry off the cover cap and remove the regulator mounting bolts.
  14.  



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Fig. Removing the top assembly carrier

  1. Remove the bolts indicated by the arrows and remove the top from the assembly carrier off of the door.
  2.  
  3. Lift and remove the assembly carrier from the door toward the hinges.
  4.  
  5. Turn the assembly carrier and disconnect the connector from the door lock; unclip the clips for the electrical cables on the back of the assembly carrier.
  6.  
  7. Punch out the clips with a drift.
  8.  



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Fig. Punching out the clips



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Fig. Removing the door lock assembly: clip (1), cable (2), screwdriver (3), door lock (4)

  1. Unclip the cable (2) from the clip (1).
  2.  
  3. Pry the door lock (4), with an assistant, off of the assembly carrier, using a screwdriver (3).
  4.  
  5. Unclip the securing rod. Turn the door lock (to assist unclipping the rod) and unclip the cable. Turn the cable nipple 90° and remove it from the eye.
  6.  

To install

  1. Insert the assembly carrier into the door.
  2.  
  3. Install the bolts and tighten in the prescribed sequence.
  4.  
  5. Loosen the clamps, push the window into the window guides, and tighten the clamps with the bolts.
  6.  
  7. The remainder of installation is in reverse order of removal.
  8.  

ADJUSTMENT
A4 & Passat
FRONT DOOR LOCK ASSEMBLY


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Fig. Removing and installing the securing rod for the lock cylinder

  1. Insert the lock cylinder securing rod into the socket at the release lever and snap it into place.
  2.  
  3. Tilt the operating clip 90° (not shown), and insert it into the door lock release lever. Tilt the back upward.
  4.  
  5. Clip the securing rod into the operating clip.
  6.  


CAUTION
Do NOT bend the locking lever at the door lock; maximum play allowable at the locking lever is 1mm.

  1. Slide the casing up on the operating clip.
  2.  



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Fig. Adjusting the locking lever play

  1. Insert the securing rod into the operating clip, so that the dimension at the locking lever is approximately 1mm.
  2.  
  3. During this step, the dimension of 13mm (adjustment depth for the securing rod) must be maintained.
  4.  
  5. After adjusting the lock correctly, slide the casing from the operating clip upward.
  6.  



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Fig. Adjustment depth for securing rod. Dimension of the securing rod must be 13mm when properly adjusted

 
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