Volkswagen Cars 2000-05

Doors

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Adjustment





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Fig. Removal of the door striker may require a Torx® style driver

  1. When checking door alignment, look carefully at each seam between the door and body. The gap should be even all the way around the door. Pay particular attention to the door seams at the corners farthest from the hinges; this is the area where errors will be most evident. Additionally, the door should push against the weather strip when latched to seal out wind and water. The contact should be even all the way around and the stripping should be about half compressed. The position of the door can be adjusted in three dimensions: fore and aft, up and down, in and out. The primary adjusting points are the hinge-to-body bolts.
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  3. Apply tape to the fender and door edges to protect the paint. Two layers of common masking tape works well.
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  5. Loosen the bolts just enough to allow the hinge to move. With the help of an assistant, position the door up and down as required and snug the bolts.
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  7. Inspect the door seams carefully and repeat the adjustment until correctly aligned.
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  9. Inspect the front door seal and determine how much it is being crushed. If there is little or no contact in this area, or if the door is recessed into the body at the front when closed, loosen the hinge-to-door bolts and adjust the door in or out as needed. Don't worry about the latch yet.
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  11. Make sure the door moves smoothly on the hinges without binding. When the door fits the opening correctly, tighten the bolts.
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  13. To adjust the latch, loosen the large cross-point screw holding the striker on the door jam on the body. These bolts will be very tight; an impact screwdriver is the best tool for this job. Make sure you are using the proper size bit.
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  15. With the bolts just loose enough to allow the striker to move if necessary, hold the outer door handle in the released position and close the door. The striker will move into the correct location to match the door latch. Open the door and tighten the mounting bolts. The striker may be adjusted towards or away from the center of the car, thereby tightening or loosening the door fit. The striker can be moved up and down to compensate for door position, but if the door is correctly mounted at the hinges this should not be necessary.
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NOTE
Do not attempt to correct height variations (sag) by adjusting the striker.

  1. After the striker bolts have been tightened, open and close the door several times. Observe the motion of the door as it engages the striker; it should continue its straight-in motion and not deflect up or down as it hits the striker.
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  3. Check the feel of the latch during opening and closing. It must be smooth and linear, without any trace of grinding or binding during engagement and release. It may be necessary to repeat the striker adjustment several times (and possibly re-adjust the hinges) before the correct door-to-body fit is achieved.
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The door alignment within the door opening in the body shell is adjusted my loosening the hinge bolts and moving the door as necessary. The door closure is adjusted by moving the latch pin or bracket.

The door hinges should be adjusted such that;

  1. The door shell is level with the lower door jamb.
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  3. On front doors, the forward edge of the door is even with, or slightly recessed, not to exceed 0.040 inches (1mm), relative to the rear portion of the front fender.
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  5. On rear doors, the forward edge of the door is even with, or slightly recessed, not to exceed 0.040 inches (1mm), relative to the rear edge of the front doors, which can be accomplished by moving the hinges of the rear door or, by moving the striker pin or bracket of the front door if the front door closure is properly adjusted.
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The closure of the doors is accomplished by moving the latch pin or bracket on the door pillar. The latch brackets are secured by 2 fasteners that are loosened to allow the bracket to be moved. The latch pin is adjusted by turning it counterclockwise to loosen it, moving it to the desired position and then tightening it. Use either a thin wall deep well socket or a boxed end wrench to loosen or tighten it.

  1. Adjust the closure of the doors by loosening and moving the latch pin or bracket on the door pillar such that;
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    1. On front doors, with the door closed, the rear edge of the door is slightly above the leading edge of the rear door, not to exceed 0.040 inch (1mm). Note, if the door has a tendency to rattle over bumps, check and adjust the height of the latch pin or bracket as necessary.
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    3. On rear doors, with the door closed, the rear edge of the door is slightly above the adjoining body panel, not to exceed 0.040 inch (1mm). Note, if the door has a tendency to rattle over bumps, check and adjust the height of the latch pin or bracket as necessary.
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On Audi A4 models the upper door window frame can be adjusted with the help of an assistant as follows;

  1. Remove the door panel.
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  3. Loosen the 2 rear and the upper front fasteners that secure the window frame to the vehicle just enough the window frame can be moved, but tight enough to hold its position. Loosen the front lower fastener such that it is just touching the door shell.
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NOTE
The front lower faster has a graduated wedge installed between the window frame and the door shell.

  1. Have the assistant sit in the vehicle and firmly press upward on the upper window frame toward the roof and the A-pillar, while, from the outside the fit of the window carrier is observed, making sure it is properly seated, then have the assistant slide the graduated wedge as necessary to retain the position.
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  3. Open the door and tighten the window carrier-to-door shell mounting bolts to 22 ft. lbs. (30 Nm).
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  5. Close the door and recheck the adjustment. If necessary, repeat the adjustment procedures to attain the proper adjustment.
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  7. Once the adjustment is completed, reinstall the door panel.
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Fig. The latch bracket shown is moved by loosening the mounting fasteners and sliding it as necessary. Matchmark the bracket to the door pillar before moving-1.8L Passat model shown

Removal & Installation





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Fig. Exploded view of a typical VW rear door



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Fig. Typical VW front passenger side door

  1. Open the door and support it securely with a floor jack or blocks. Remove the door check strap sleeve and remove the door check strap.
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  3. If necessary, remove the door panel to disconnect the wiring for speakers, electric windows, electric mirrors and the air line for power door locks.
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  5. Have an assistant steady the door and remove the hinge bolts to remove the door.
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  7. Installation is the reverse of removal.
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  1. Apply a protective layer of masking tape to the leading, lower and rear edges of the door and the rear edge of the front fender.
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  3. If desired, or on vehicles with electric windows, if disassembling the door, roll the window down before removing the door.
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  5. Disconnect the large hex shaped electrical connector on the lower A-pillar by turning it counterclockwise.
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  7. Remove the lower A-pillar interior trim to and disconnect the door wiring electrical connectors.
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  9. Remove the bellows and guide the wires out away from the door jamb.
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  11. Remove the protective cap on the upper hinge and remove the setscrew using a suitable hex tool.
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  13. Remove the lower hinge-to-door bolt.
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  15. Grasp the door firmly and lift upward to remove.
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  17. Installation is in reverse order of removal noting the following:
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  19. Install the setscrew and torque to 17 ft. lbs. (23 Nm).
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  21. Replace the lower hinge bolt and torque to:
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Passat models:



Step 1: 15 ft. lbs.
 
Step 2: 90° ( 1 / 4 turn)
 

A4 models:



22 ft. lbs. (30 Nm)
 

 
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