Volkswagen Cars 2000-05

Locks & Lock Systems

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Adjustment



A4 & Passat
Front Door Lock Assembly


Click image to see an enlarged view

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.  



Click image to see an enlarged view

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.  



Click image to see an enlarged view

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

Power Door Locks



Removal & Installation
Door Lock Motor
  1. Remove the front door trim, as outlined in this section.
  2.  
  3. Removing the lock cylinder housing, as follows:
    1. Pry out the cap.

      Click image to see an enlarged view

      Fig. Pry out the cap (3)

    2.  
    3. Pull door handle out and secure in this position. Remove the bolt using torque wrench T10011 (socket wrench T10072 introduced as running change) until stop. The lock cylinder housing is loosened by performing this.
      NOTE
      If bolt is loosened too much, the lock mechanism ring will loosen from mounting bracket and fall into the door.

    4.  
    5. Remove the lock cylinder housing at a right angle to door from the door handle mounting bracket.

      Click image to see an enlarged view

      Fig. Pull the door handle (1) out and secure, unfasten the bolt (2), then remove the lock cylinder housing (2)

    6.  

  4.  
  5. Unfasten the clip from the door handle.

    Click image to see an enlarged view

    Fig. Unclip the clip (1) from the door handle

  6.  
  7. Pry off the caps.
  8.  
  9. Lower the window until securing bolts of door window are accessible.
    NOTE
    If the preceding step is not possible because the power window is not working, the window regulator motor can be removed to be able to slide window down.

  10.  
  11. Loosen the bolts, then press the clamping brackets apart.

    Click image to see an enlarged view

    Fig. View of the caps (1) and bolts (2) and bolts (arrows)

  12.  
  13. Slide door windows upward and secure (e.g. using adhesive tape).
  14.  
  15. Disconnect all connectors.
  16.  
  17. Unfasten the bolts.
  18.  
  19. Remove bolts . Remove upper carrier assembly from door, lift and lift out from door toward door hinges.
  20.  
  21. Rotate carrier assembly and disconnect connector from door lock.
  22.  
  23. Then, unclip clips for electrical wires from rear side of carrier assembly.
  24.  
  25. Drive out the clips using a drift.

    Click image to see an enlarged view

    Fig. Use a drift to drive out the clips (1)

  26.  
  27. Unclip the cable from the clip.
  28.  
  29. Using a prytool, pry off door lock with assembly aid from carrier assembly.
    NOTE
    The angle bracket is not part of parts supplied with door lock. It is secured to door lock with a bolt and a blind rivet.



    Click image to see an enlarged view

    Fig. Unclip the cable (2) from the clip (1). Using a prytool (3), pry off door lock with assembly aid from carrier assembly

  30.  
  31. Unclip the locking rod by turning the door lock in the direction of the arrow as shown in the illustration.
  32.  
  33. Unclip the cable.
  34.  
  35. Rotate the end of cable 90° and remove from eyelet.

    Click image to see an enlarged view

    Fig. Unclip the locking rod (1) by turning the door lock in the direction of the arrow. Unclip the cable (2)

  36.  

To install:

  1. Pull the operating lever (1) in direction of the arrow, as shown in the illustration.
  2.  
  3. Using a screwdriver, tension spring (2) secured to door lock in direction of the arrow and engage lock lever into spring.
    NOTE
    Lock is secured by engaging operating lever. Thereby later incorrect clipping-in of Bowden cable is prevented.



    Click image to see an enlarged view

    Fig. Pull the operating lever (1) in direction of the arrow, as shown in the illustration. Using a screwdriver, tension spring (2) secured to door lock in direction of the arrow and engage lock lever into spring

  4.  
  5. Insert carrier assembly into door.
  6.  
  7. Tighten all bolts to 71 inch lbs. (8 Nm). Tighten the bolts marked (1) and (2) in the illustration, in the reverse order of removal. The remaining bolts can be tightened in any sequence.
  8.  
  9. Press door window (3) into window guide - arrow - and tighten clamping brackets with bolts (4). Tighten the plastic clamping brackets to 7 ft. lbs. (9 Nm), and the aluminum clamping brackets to 8 ft. lbs. (11 Nm).

    Click image to see an enlarged view

    Fig. Tighten bolts (1) and (2), in the reverse order of removal. The remaining bolts can be tightened in any sequence. Press the door window (3) into the window guide (arrow) and tighten clamping brackets with the bolts (4)

  10.  
  11. The remainder of installation is the reverse of the removal procedure.
  12.  
  13. Note the following when installing the door lock cylinder housing:
    1. Insert lock cylinder housing at right angle into door handle mounting bracket.
    2.  
    3. Now screw in bolt into mounting bracket using torque wrench.
    4.  
    5. The door handle should engage again into lock cylinder housing with a very audible click.
      NOTE
      During installation, the door handle and lock cylinder housing must be pressed onto door plate.

    6.  
    7. Then, perform in reverse order of removal.
    8.  

  14.  
  15. Make sure the door and door locks are operating properly.
  16.  

Removal & Installation



  1. To replace the pump, remove the left luggage compartment interior panel and remove the pump cover and the pump. Test the new pump before completing the installation.
  2.  
  3. To replace the actuator, remove the door panel. Follow the hose to the actuator and disconnect the hose and the linkage at the actuator. On the driver's door, disconnect the wiring.
  4.  
  5. Remove the screws and remove the actuator. Connect the hose to the new actuator and test the system before installing it.
  6.  



Click image to see an enlarged view

Fig. Removing the latch from the tailgate



Click image to see an enlarged view

Fig. Remove the bolts from the lock



Click image to see an enlarged view

Fig. Pull the lock from the tailgate

  1. Open the hatch and remove the lock mounting bolts.
  2.  
  3. Lower the lock assembly to gain access to the
  4.  
  5. Pull the lock mechanism from the tailgate
  6.  

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.



Click image to see an enlarged view

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.  



Click image to see an enlarged view

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.  



Click image to see an enlarged view

Fig. Punching out the clips



Click image to see an enlarged view

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.  

Manual Door Locks


Click image to see an enlarged view

Fig. Typical VW door lock assembly

  1. Remove the door panel.
  2.  
  3. Disconnect the linkage and remove the screws to remove the lock from the door.
  4.  
  5. When installing, hold lever A at a 90 degree angle and secure it with a screwdriver.
  6.  
  7. Insert the rod through the hole in the door and connect the lock linkage.
  8.  
  9. Remove the screwdriver, install the screws and connect the latch linkage.
  10.  

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).

Testing



The heart of the pneumatic central locking system is the bi-pressure pump mounted in the luggage compartment. The pump runs both ways to provide vacuum or pressure as required for locking or unlocking. There are lock actuators at each door, the rear hatch or trunk and at the fuel filler door. The master actuator at the driver's door includes the switch that activates the pump. In normal operation, the pump runs for about 2 seconds and will build enough pressure or vacuum to operate all locks and activate an internal shut-off switch. If the pump runs for more than 5 seconds, a leak in the system is preventing shut-off switch operation and an automatic shut-off will occur in about 35 seconds. If the pump does not run at all, the problem is most likely electrical.

  1. Open the luggage compartment and remove the left side interior trim. Unhook the strap, remove the pump cover and pull the pump out of the housing.
  2.  
  3. Install a small clamp on the hose before the first branching tee and turn the key in the driver's door lock. If the pump does not run at all, go to Step 7.
  4.  
  5. If the pump runs for more than 5 seconds, the shut-off switch inside is faulty and the pump must be replaced. If the pump stops in less than 5 seconds, the pump is good and there is a leak somewhere in the system.
  6.  
  7. Move the clamp to the upper branch of the tee and turn the driver's door lock again. If the pump runs too long, the leak is at the left rear door actuator or the hose.
  8.  
  9. If the pump stops in less than 5 seconds, move the clamp to the next hose junction at the right rear of the luggage compartment and test again. The hose that branches to the right supplies the fuel filler door and trunk or hatch actuator. The hose branching down supplies the right door actuators.
  10.  
  11. Continue moving the clamp towards the actuators until the pump does not stop within 5 seconds. This means the clamp is now past the leak and the previous section of hose or actuator is leaking.
  12.  
  13. If the pump does not run at all, disconnect the wiring and connect a voltmeter or test light to the center and right terminals on the connector. There should be 12 volts when the driver's door is unlocked.
  14.  
  15. Move the tester to the center and left terminals. There should be 12 volts when the driver's door is locked.
  16.  
  17. If the voltages appear as specified, the pump is faulty and must be replaced. If there is no voltage in either or both tests, the lock switch, wiring or fuse is faulty. The switch is part of the master actuator and cannot be replaced separately.
  18.  

 
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