VW Passat & Audi A4 1990-2000

Tailgate/Hatch/Liftgate Lock

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REMOVAL & INSTALLATION
Passat


Click image to see an enlarged view

Fig. Exploded view of the rear hatchback door lock assembly: carrier (1), exterior handle assembly (2), door handle trim (3), handle (4), door handle lever (5), pop rivet nut (6), registration plate (7), lock latch assembly (8), relay lever (9), lever (10), central locking actuator (11), operating rod (12), connector sleeve (13), relay lever (14)

The lock cylinder can only be removed in conjunction with the carrier (1).

  1. Remove the exterior handle assembly (2) attaching nuts.
  2.  
  3. Remove the door handle trim (3) by unscrewing the hex nuts and taking the outer hand grip off of the tailgate.
  4.  
  5. Remove the handle (4).
  6.  
  7. Remove the door handle lever (5).
  8.  
  9. Note the location of the pop rivet nut (6).
  10.  
  11. Remove the base for the registration plate (7).
  12.  
  13. To remove the lock latch assembly (8):
  14.  
    1. Remove the tailgate trim.
    2.  
    3. Disconnect the connector on lock.
    4.  
    5. Unclip the operating rod (12), unscrew nuts and take lock out of rear lid/tailgate.
    6.  

  15. Remove the relay lever (9) for the latch assembly
  16.  
  17. Remove the relay latch assembly relay lever nut and remove the lever (10).
  18.  
  19. To remove the central locking actuator (11):
  20.  
    1. Remove the lock cylinder carrier.
    2.  
    3. Unbolt the actuator (11) and it allow to hang.
    4.  

  21. To remove the operating rod:
  22.  
    1. Press the relay lever (14) against its stop and insert the operating rod, free of tension.
    2.  
    3. Remove the connector sleeve (13).
    4.  
    5. Remove the relay lever (14).
    6.  


To remove the lock cylinder from the carrier:

  1. Unclip the operating rod (12) for rear lid/tailgate lock.
  2.  
  3. Release the securing clip by turning it counterclockwise with a screwdriver and hold in this position.
  4.  
  5. Pull the lock cylinder carrier off of the tailgate/rear lid and off of the outer hand grip.
  6.  
  7. The lock cylinder can now be taken out of the carrier.
  8.  

To install:

Installation is in reverse order of removal.


NOTE
Install the complete carrier onto the outer grip and the studs. Engage it into the outer grip (a clicking must be heard).

Audi A4


Click image to see an enlarged view

Fig. Exploded view of the rear trunk lock assembly and lid components

  1. Remove the rear lid lock (3) after unscrewing the retaining nuts (8).
  2.  
  3. Remove the locking cylinder (4):
  4.  
    1. Disconnect the vacuum line for central locking system.
    2.  
    3. Disconnect the harness connectors.
    4.  
    5. Unclip the operating rod (9).
    6.  
    7. Remove the cylinder bolts (7).
    8.  

  5. Remove the lock assembly (3).
  6.  

To install

Installation is in reverse order of removal

ADJUSTMENT
Audi A4
  1. Loosen bolt (11) and detach the stop buffer.
  2.  
  3. Tighten bolt (11) finger-tight (it must still be possible to move the stop buffer).
  4.  
  5. Carefully close the rear lid until the lid (2) is flush with the rear side panels.
  6.  
  7. Now, carefully open the rear lid.
  8.  
  9. Pull the stop buffer out 2 catches (1mm preload) and tighten the bolt (11) to 49-57 inch lbs. (5.5-6.5 Nm).
  10.  

 
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