b3 57 front doors

Volkswagen B3 Passat Body Exterior 57 Body - Front Doors (Page GR-57)

Central door lockingassembly (Sedan)assembly (Wagon)bi-pressure pump checkinggas flap activatormaster activators rear door activators pump/module location troubleshooting multi-point connector, identification

Front doorassemblyassembly, w/pwr windowsglass, removing/installing inner door opening mechanism, removing/installing inner seal, removing/installing lock, assembly lock, removing/installing lock, removing/installing with freeplay adjustment lock cylinder, installingmicroswitch, removing/installing removing/installing

Impact barassembly

Outer window channelremoving/installing

Power window control modulelocation/terminal identification

Window regulatorremoving/installingremoving/installing w/power windows

Volkswagen B3 Passat Body Exterior Front door, assembly (Page 57-10-1)

1 - Hinge bolted to door, inserted into A-pillar. secured with grub screw

2 - Trim plate, inner/outer pull off

3 - Window channel, outer mounted to window frame, cannot be removed without destroying, removing/installing, see section 57-50

4 - Glassremoving/installing, see section 57-40mounting on window regulator, see section 57-40mounting dimensions on window carrier, see section 57-40

5 - Doorremoving/installing, see section 57-20elongated holes in hinge 1 are for adjustment

6 - Window slot seal, outer

mounted onto door body flange7 - Window slot seal, inner

mounted onto door body flange

Volkswagen B3 Passat Body Exterior Front door, assembly (Page 57-10-2)

8 - Window channel, inner mounted into door body flange

9 - Guide rail, rear10 - 7.0 Nm (5.2 ft lb)11 - Window regulator

removing/installing, see section 57-30installing glass to regulator, see section 57-40

12 - Bearing sleeve with collarremove before regulator is removedreplaces bearing sleeve 13 without collar

13 - Bearing sleeve without collar install with seal 14, only 12 available as replacement

14 - Seal for 13, if damaged, replace with 12

15 - Cover for 16

16 - Door check17 - 7.0 Nm (5.2 ft lb)18 - Clip19 - Lock nut -65 Nm(4.8 ft lb)20 - Guide rail, front

removing, push downward and toward inside of door21 - 55 Nm (42 ft lb)22 - Door check, outer cover

self adhesive, mounted to A-pillar

Volkswagen B3 Passat Body Exterior Front door, assembly: Power windows (7-15-1)

1 - Hingebolted to door, inserted into A-pillarsecured with grub screw

2 - Trim plate, inner/outer pull off

3 - Window channel, outermounted to window framecannot be removed without destroyingremoving/installing, section 57-50

4 - Glassremoving/installing, see section 57-40mounting on window regulator, see section 57-40mounting dimensions on window carrier, see section 57-40

5 - Doorremoving/installing, see section 57-20elongated holes in hinge 1 are for adjustment

6 - Window slot seal, outer mounted onto door body flange

7 - Window slot seal, inner8 - Window channel, inner

mounted onto door body flange9 - Guide rail, rear

10 - Bolt - 7.0 Nm (62 in. lb)

Volkswagen B3 Passat Body Exterior Front door, assembly: Power windows (Page 57-15-2)

11 - Window regulatorremoving/installing, see section 57-30installing glass to regulator

12 - Window regulator motor13 - Cover14 - Door check15 - Bolt - 7.0 Nm (62 in. lb)16 - Clip17 - Lock nut - 6.5 Nm (66 in. lb)18 - Guide rail, front

removing, push downward and toward inside of door19 - Bolt - 55 Nm (42 ft lb)20 - Outer cover, door check

self adhesive mounted to A-pillar

Volkswagen B3 Passat Body Exterior Door, removing/installing (Page 57-20-1)

NoteIf vehicle equipped with central door locking and power windows, door trim panel must be removed, and electrical wiring going into door disconnected.Removing

remove nut 6, pull out pin A from door checkremove grub screws (arrow) from hingeslift door up and out of hinge bracket

InstallingReinstall in reverse order of removal, noting the following:

clean pin A and nut threads with wire brush, and coat pin with locking compound AMV 197 000 01 or equivalenttorque nut 6

6.5 Nm (4.8 ft lb)

Volkswagen B3 Passat Body Exterior Window regulator, removing/installing (Page 57-30-1)

Removingremove door trim panel

disconnect wiring for central door locking, power operated windows, if applicableunbolt glass from regulator (arrows)push glass and secure fully upwards

hold and secure in place with tapepull bearing sleeve 12 off regulator pivotlift regulator until retaining lugs are free, then remove regulator

InstallingReinstall all components in reverse order of removal.

Volkswagen B3 Passat Body Exterior Window regulator, removing/installing: Power windows (Page 57-35-1)

Removingremove door trim panel retaining screwsremove door trim panel, see Repair Group 70remove door handle cover and handle

remove inner door release leverslide rearward in direction of arrow

disconnect power mirror connector at control switchremove upper door trim panel and disconnect power window control switchremove power window control switch from door trim panel

CAUTION!DO NOT damage the plastic moisture barrier. Water leaks will occur if damaged moisture barriers are installed.Always replace damaged moisture barriers.

remove lower door panel retaining screwsremove lower door paneldisconnect speakerspush retainer pins into door on door trim panel mountsremove mountsremove door release lever assembly from door by sliding rearwardcarefully remove door plastic moisture barrierreconnect power window switchswitch ON ignition

lower window regulator until mounting bolts for glass are visible in holes 3loosen bolts and removeraise regulator to top position and tape glass in placelower regulator 1/2 waydisconnect power window switch


remove regulator mounting bolts (arrows)remove window regulator and motor

remove Allan head screw from back of stop disc 1remove disc

note position of stops on disc

remove motor mounting bolts (arrows) and take out motorInstallingReinstall all components in reverse order, noting the following:

install window regulator motor onto window regulatorinstall stop disc onto regulator, and secure with allen screw

note position of stops on discrecover push pins from door trim panel mounts inside of door


reinstall window regulator into door with mounting bolts (arrows)note position of retaining lugstorque mounting bolts 7.0 Nm (62 in. lb)

reconnect power window motor

install black plastic guide arm 1 onto rear guide rail 2lower window regulator until window glass mounting holes are visible in large opening in bottom of door sheet metalremove tape securing glass, and lower glass onto regulatorlightly tighten glass to regulator assemblyfully raise window, then lower until bolts are visible in holes 3tighten bolts

7.0 Nm (62 in. lb)lower glass with regulator until lower slide rail is visible in lower opening of door shellensure glass is set into front guide railensure black plastic guide arm 1 is set onto rear guide rail 2check front to rear movement of door glass

must not exceed 5.0mm (approx. 13/64 in.)

NoteIf front to rear movement of glass exceeds 5.0 mm (approx. 13/64 in.) the glass will not stay in front guide rail when raised.Check for bent guide rails. The front guide rail may be replaced as necessary. The rear guide rail is part of the door shell, and can only be straightened.

align front and rear guide rails as necessary


NoteThe lower mounting hole may have to be elongated to align the front window guide. The rear guide rail may need to be tapped rearward with a hammer or mallet.Apply corrosion protection to elongated hole.

operate window in both directions at least 10 times to ensure correct operationdisconnect power window control switchreinstall plastic moisture barrier

wrinkle freereinstall all other door trim components in reverse order of removal

Volkswagen B3 Passat Body Exterior Power window control module, location/terminal identification (Page 57-36-1)

LocationThe power window control module is located beneath the rear bench seat.Connector terminal identification

11 = T 8a/1 12 = T 8a/2 13 = T 8a/3 14 = T 8a/4 15 = T 8a/5 16 = T 8a/6 17 = T 8a/7 18 = T 8a/8

21 = T 8c/1 22 = T 8c/2 23 = T 8c/3 24 = T 8c/4 25 = T 8c/5 26 = T 8c/6 27 = T 8c/7 28 = T 8c/8

31 = T 8b/1 32 = T 8b/2 33 = T 8b/3 34 = T 8b/4 35 = T 8b/5 36 = T 8b/6 37 = T 8b/7 38 = T 8b/8

Connector colorsT 8a - BrownT 8b - WhiteT 8c - BlackNoteSee wiring diagram for wire routing to connectors T 8a, T 8b and T 8c. Always refer to appropriate wiring diagram when performing any electrical tests or repairs.

Volkswagen B3 Passat Body Exterior Door glass, removing/installing (Page 57-40-1)

Removingremove door trim panelpull off inner door window slot sealfully lower windows and secure in lowest positionunbolt glass from regulatortilt and lift glass out of door as shown

InstallingReinstall all components in reverse order of removal, noting the following:

if glass was removed from carrier 1, remount as shown a = 303 mm (approximately 11.8 in.)

install guide arm rail 1 to guide rail 2bolt glass to regulator

do not fully tightenfully raise window, then lower until bolts are visible in holes 3fully tighten bolts

7.0 Nm (5.2 ft lb)

Volkswagen B3 Passat Body Exterior Outer window channel, removing/installing (Page 57-50-1)

Removingremove inner/outer trim platespull off outer window slot sealpull off inner window slot sealstarting at upper corner, carefully snap (pry) off outer window channel from door flange, as shown

Installing

tilt channel into window slot at rearstarting at upper corner, press channel downward onto door flange

retaining lip (arrow B) must engage flange fullyreinstall all other components

Volkswagen B3 Passat Body Exterior Impact bar, assembly (Page 57-60-1)

NoteImpact bar is located under the protective molding A.

1 - 25 Nm (18 ft lb)2 - Washer3 - Grommet4 - Impact bar

Volkswagen B3 Passat Body Exterior Door lock, assembly (Page 57-70-1)

1 - Support rotate 90 (1/4 turn) to remove

2 - Door handle removing/installing,see section 57-100 in vehicles with central door locking, door trim panel must be removed and connector 6 pulled off Reduce free play on door handle by turning adjuster 7

3 - Lock cylinder remove only with key when reinstalling, lubricate with grease G 000 400 or equivalent

4 - Gasket5 - Clamp6 - Connector, central door locking7 - Adjuster

Adjustable, reduces free play at door handle between adjuster and lock operating lever 19 = 0.1 - 1.0mm (approx. 0.004 - 0.039 in)

adjusting: remove door handle or adjust from inside door if vehicle equipped with central door locking

8 - Screw w/washer 7.0 Nm (5.2 ft lb)

9 - Lock rod

Volkswagen B3 Passat Body Exterior Door lock, assembly (Page 57-70-2)

10 - Lock knob screwed on 9

11 - Locking lever12 - Microswitch

for automatic shoulder belt system only13 - Door lock

removing: door glass must be fully raised (closed)if necessary, adjust free play between lock and door handle

14 - Striker bolt -50 Nm (37 ft lb)15 - Washer

collar faces away from B-pillar16 - Plastic washer17 - 20 Nm (15 ft lb)18 - Seal

must match door lock19 - Operating lever

insert into inner door opening mechanism from underneath20 - Circlip21 - Clip22 - Swivel bushing23 - Spring24 - Inner door opening mechanism

removing, see section 57-120

Volkswagen B3 Passat Body Exterior Door lock, removing/installing (Page 57-75-1)

Door lock with freeplay adjustment as of Jan. 19921. Door handle2. Door lock with freeplay adjustment3. Bolt

20 Nm (15 ft lb)4. Cap5. Nut

freeplay adjustmentRemoving- unclip cap -4-- remove bolt -3-- pull away door lock -2- slightly and lock operating lever with 3mm mandrel- pull out door lock and unhook pull rod from inner lock mechanism


- loosen nut -3- with 5.5mm wrenchrelease lever will give wayright side = left hand threadleft side = right hand thread

1 Assembly position

- install door lockfreeplay adjustment actuated between release lever and actuating lever

2 Installed position

- tighten nut -3-, use torque wrench VAG 1783 and insert VAG 178424 Nm (2 in.lb)

- make adjustment after every removal of door handle or door lock- check proper function

Volkswagen B3 Passat Body Exterior Door handle, assembly (Page 57-80-1)

1 - Lock cylinderremove with key inserted do not lose spring 2, ball 3 on passenger handle, ball may be located between microswitch 6 and handle 5lubricate lock cylinder with grease G 000 400 or equivalent

2 - Spring do not lose when removing lock cylinder 1

3 - Ball do not lose when removing lock cylinder 1 located between microswitch 6 and handle 5 on passenger side

4 - Sealing ring5 - Door handle

with electrical connection for central door locking disconnect before removing

6 - Microswitch cannot be removed

7 - Mounting hole

for ball 3, spring 28 - Bushing

adjusts free play in door handle. Free play between bushing and lever from lock 0.1-1.0 mm (0.004-0.039 in.)

Volkswagen B3 Passat Body Exterior Door handle, assembly (Page 57-80-2)

9 - Circlip10 - Swivel bushing

install with spring 1111 - Spring12 - Seal


Removingremove door trim panelpartially pull off plastic moisture barrier.disconnect wire to lock on vehicles with automatic shoulder belt systeminsert 3.0 mm (1/8 in.) punch as shown and lock operating lever (arrow)

open door from insideremove screws A

InstallingReinstall all components in reverse order noting the following:

check tolerance (free play of door handle) between adjuster and door lock operating lever, adjust if necessary

0.1-1.0 mm (0.004-0.039 in.)screws A 20 Nm (15 ft lb)

Volkswagen B3 Passat Body Exterior Door handle, removing/installing: Left side - all VIN numbers, Right side - up to Vin NE 190 000 (Page 57-100-1)

RemovingNoteon vehicles with central door locking, remove door trim panel, pull back plastic moisture barrier and disconnect wire to handle.

remove screw Apush door handle in direction of arrow and pivot out of door

InstallingReinstall all components in reverse order, noting the following:

clip and route wire to lock on vehicles with central door locking so not to interfere with lock operationcheck washer 2 and clip 3 for damagecheck tolerance (free play of door handle) between adjuster and operating lever. If necessary adjust by turning adjuster

0.1-1.0 mm (0.004-0.039 in.)screw A, 7.0 Nm (5.2 ft lb)

Volkswagen B3 Passat Body Exterior Right side door handle, removing/installing: From VIN NE 190 000 (Page 57-105-1)

RemovingNoteMounting screw 1 on right side door handle now has left hand threads.On vehicles with central door locking, remove door trim panel, pull back plastic moisture barrier and disconnect wire to handle.

remove mounting screw 1left hand threads

push door handle in direction of arrow A and pivot out of doorInstallingReinstall all components in reverse order, noting the following:

clip and route wire to lock on vehicles with central door locking so not to interfere with lock operationcheck washer 2 and clip 3 for damagecheck tolerance (free play of door handle) between adjuster and operating lever. If necessary adjust by turning adjuster

0.1-1.0 mm (0.004-0.039 in.)tighten screw 1

7.0 Nm (5.2 ft lb)

Volkswagen B3 Passat Body Exterior Lock cylinder, installing (Page 57-110-1)

install gasket on lock cylinder as shownslightly pull back gasket (arrow) at area of microswitchslightly pull outside door handle and hold

as if opening doorinsert lock cylinder sufficiently until hole in cylinder and housing are covered.coat ball with grease and place on spring

push ball with spring into lock with tool 1, as showntool is small diameter tube. 2.5 mm (3/32 in.) by approximately 50 mm (2.0 in) long

turn lock cylinder to stop, then an additional 90

check that ball is visible in gap between lock cylinder housing and lock cylinder (arrow)check that lock cylinder rotates approximately 70 to either sideinstall circlip onto end of lock cylinderposition swivel bushing with springpush ends of spring backspring should touch tab protruding from lock cylinder housing

swivel bushing is correctly fitted if lock ring groove is not coveredinstall lock ringcheck lock cylinder for proper function

spring must always return lock cylinder to center position

Volkswagen B3 Passat Body Exterior Inner door opening mechanism, removing/installing (Page 57-120-1)

Removinginsert screwdriver as shown, and pry out securing clip from hole in door panelpush out inner door opening mechanism in direction of arrow

InstallingReinstall all components in reverse order of removal.

Volkswagen B3 Passat Body Exterior Door microswitch, removing/installing (Page 57-130-1)

Removingpry microswitch out of tabs (arrows)

Installingclip into tabsroute wires through clip A

Volkswagen B3 Passat Body Exterior Door inner seal, removing/installing (Page 57-140-1)

Removingremove inner trimremove seal

InstallingReinstall all components in reverse order of removal, noting the following:

door inner seal starts at point 2a = 520 20 mm (approximately 20 3.0 in.) from front lower corner of door opening

Volkswagen B3 Passat Body Exterior Central door locking, assembly: Sedan (Page 57-150-1)

1 - Bi-pressure pump located under trim, left side trunk installing, section 57-170

2 - T-connector located by Bi-pressure pump

3 - Activator, rear doors removing/installing, section 57-200

4 - T-connector located at base of B-pillar, covered by door sill

5 - Master activator, front doors removing/installing, section 57-190

6 - Activator, gas flap loosen truck trim to remove, removing/installing section 57-180

7 - Activator, rear lid removing, open hinge on activator, unhook connecting rod

8 - T-connector located at wheel house/seatback under trunk carpet

Volkswagen B3 Passat Body Exterior Central door locking, assembly: Wagon (Page 57-160-1)

1 - Activator, gas flaplocated in right rear, remove right side loading area trim, and loosen right front loading area trimremoving/installing, section 57-180

2 - Foam tubing3 - T-connector

located near fuel tank lid activator4 - Activator, tailgate

remove tailgate trim for access5 - Grommet6 - Activator, rear doors

removing/installing, section 57-2007 - Master activator, front doors

removing/installing, section 57-1908 - T-connector

located at base of B-pillar/side member covered by door sill trim

9 - Bi-pressure pump located in depression at right rear floor

10 - T-connector located behind right wheel house

11 - T-connector located between wheel house and seatback, covered by front loading area trim

Volkswagen B3 Passat Body Exterior Bi-pressure pump, installing (Page 57-170-1)

insert pressure lineinstall multi-point connector to bi-pressure pump

ensure terminal 1 (4-pin) is secured by clipdo not pinch sunroof drain hose 2 when reinstalling bi-pressure pumpreinstall sound deadener around bi-pressure pumpreinstall trunk trim

Volkswagen B3 Passat Body Exterior Gas flap activator, removing/installing (Page 57-180-1)

Removingloosen screwsunhook activator with lock rod from lock guide 3pull off pressure/vacuum hose A

InstallingReinstall in reverse order, noting the following:

check gas flap activator for proper function before reinstalling luggage compartment trim

Volkswagen B3 Passat Body Exterior Master activators, removing/installing (Page 57-190-1)

Removingremove door panel trimpartially remove plastic moisture barrierdisconnect inner door opening mechanism and locking rodpull pressure/vacuum hose out of retaining clips

open hinge 4, and unhook lock rodloosen screws, remove activator from toppull pressure/vacuum hose out of activator

InstallingNoteFor lock rod assembly, activator and door lock must be in locked (closed) position.

reinstall pressure/vacuum hosereinsert screws, install and secure activatorreinstall inner door opening mechanism and locking rodlock washer 5 must be locked

push in lock rod and close hinge 4CAUTION!Do not pull lock rod downward when pushing in.NoteWhen locking, hinge 4 must turn lock washer 5 and unlock.

check plastic moisture barrier for damage or wrinklesreplace or repair as necessaryadditional two-sided tape, Part No. AKL 440 025 or equivalent may be applied

reinstall door trimcheck central locking for proper function

Volkswagen B3 Passat Body Exterior Rear door activators, removing/installing (Page 57-200-1)

Removingremove rear door trimpartially remove plastic moisture barrierunhook line from clip 6open hinge 4, and unhook lock rodloosen screws and remove activator from belowpull pressure/vacuum hose off activator

InstallingNote:For lock rod assembly, activator and door lock must be in locked (closed) position.

reinstall pressure/vacuum hosereinsert screws, install and secure activatorreinstall inner door opening mechanism and locking rodlock washer 5 must be locked (arrows)rehook lines in clip 6

push in lock rod and close hinge 4CAUTION!Do not pull lock rod downward when pushing in.NoteWhen locking, hinge 4 must turn lock washer 5 and unlock.

check plastic moisture barrier for damage or wrinklesreplace or repair as necessaryadditional two-sided tape, Part No. AKL 440 025 or equivalent may be applied

reinstall door trimcheck central locking for proper function

Volkswagen B3 Passat Body Exterior Central door locking, checking (Page 57-210-1)

NoteAll locks must close within approximately 2 seconds.If the bi-pressure pump runs longer than 5 seconds, either the linkage or the activator is not correctly adjusted or the system has leaks.The shut-off point in the activator is not attained if the linkage is not adjusted correctly - bi-pressure pump "pulses." After approximately 35 seconds the control unit must shut off the bi-pressure pump.NoteCentral locking of all activators is possible through both driver and front passenger door locks.

Volkswagen B3 Passat Body Exterior Central locking system, troubleshooting (Page 57-220-1)

NoteAlways refer to appropriate wiring diagram.Tools required

Multimeter Fluke 83

Connector Test Kit VW 1594CAUTION!DO NOT damage, enlarge or bend connector terminals or cavities by forcing probes into them when performing electrical checks. Use Connector Test Kit VW 1594 to make the necessary electrical connections.Test conditions

battery OKfuse S 16 OKfuse S 21 OKvacuum system OK, section 57-210

NoteIf one or more locks do not open or close, check if the vacuum pump remains on longer than 5 seconds, then pumps again after a short time. If so, there is a leak in the vacuum system which must be eliminated prior to troubleshooting.

Volkswagen B3 Passat Body Exterior Central locking system pump and control module, location/terminal identification (Page 57-230-1)

Location

Vehicle/model Location of central locking system pump and control module (V 69)

Passat sedan luggage compartment, left side, rear

Passat wagon luggage compartment, right side, next to spare tire molding

Connector terminal identification

1 = T 12/1 2 = T 12/2 3 = T 12/3 4 = T 12/4 5 = T 12/5 6 = T 12/6

7 = T 12/7 8 = T 12/8 9 = T 12/9

10 = T 12/10 11 = T 12/11 12 = T 12/12

Connector colorT 12 - transparentNoteSee wiring diagram for wire routing to connector T 12. Always refer to appropriate wiring diagram when performing any electrical tests or repairs.

b3 57 front doors

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