Volkswagen B3 Passat Body Exterior

58 Body - Rear Doors (Page GR-58)

Door inner seal removing/installing Impact bar assembly Outer window channel removing/installing Rear door assembly assembly, with power windows glass, removing/installing handle, removing/installing inner door opening mechanism, removing/installing lock, assembly lock, removing/installing Window regulator removing/installing

Volkswagen B3 Passat Body Exterior

Rear door, assembly (Page 58-10-1)

1 - Trim plate inner/outer 2 - 7.0 Nm (5.2 ft lb) 3 - Guide rail, rear push upward and out window slot 4 - Window regulator removing/installing, see section 58-30 installing glass to regulator, see section 58-40 5 - Sleeve cover for 7 6 - 7.0 Nm (5.2ft lb) 7 - Door check 8 - 6.5 Nm (4.8 ft lb) 9 - Clip 10 - Door check, outer cover self adhesive, mounted to B-pillar

11 - 55 Nm (42 ft lb) 12 - Hinge bolted to door, inserted into B-pillar, secured with grub screw

Volkswagen B3 Passat Body Exterior

Rear door, assembly (Page 58-10-2)

13 - Window slot seal, inner mounted onto door body flange 14 - Window slot seal, outer mounted onto door body flange 15 - Door removing/installing, see section 58-20 use elongated holes in hinge 12 to adjust 16 - Window channel, inner mounted onto door body flange 17 - Glass removing/installing, see section 58-40 mounting dimension on window carrier, see section 58-40 18 - Window channel, outer mounted to window frame

Volkswagen B3 Passat Body Exterior

Rear door, assembly: Power windows (Page 58-15-1)

1 - Door removing/installing, see section 58-20 use elongated holes in hinge 2 to adjust 2 - Hinge bolted to door, inserted into B-pillar secured with grub screw 3 - Bolt - 55 Nm (42ft lb) 4 - Door check, outer cover self adhesive; mounted to B-Pillar 5 - Clip 6 - Nut - 6.5 Nm (57 in. lb) 7 - Door check 8 - Bolt - 7.0 (62 in. lb) 9 - Sleeve cover 10 - Motor, window regulator 11 - Window regulator

removing/installing, see section 58-30 installing glass to regulator, see section 58-40 12 - Bolt - 7.0 Nm (62 in. lb) 13 - Window slot seal, inner mounted onto door body flange 14 - Window slot seal, outer mounted onto door body flange

Volkswagen B3 Passat Body Exterior

Rear door, assembly: Power windows (Page 58-15-2)

15 - Guide rail, rear push upward and out window slot 16 - Glass removing/installing, see section 58-40 mounting dimension on window carrier, see section 58-40 17 - Window channel, inner mounted onto door body flange 18 - Window channel, outer mounted to window frame removal not possible without destroying channel removing/installing, see section 58-50 19 - Cover

Volkswagen B3 Passat Body Exterior

Door, removing/installing (Page 58-20-1)

Note If vehicle equipped with central door locking and power windows, remove door trim panel and disconnect electrical wiring going into door. Removing remove nut 6, pull out pin A from door check remove grub screws (arrow) from hinges lift door up and out of hinge bracket Installing Reinstall 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 equivalent torque nut 6 6.5 Nm (4.8 ft lb)

Volkswagen B3 Passat Body Exterior

Window regulator, removing/installing (Page 58-30-1)

Removing remove door trim panel disconnect wiring for central door locking, power windows, if applicable unbolt glass from regulator push glass and secure fully upwards hold in place with tape remove bolts (arrows) and take out regulator Installing Reinstall all components in reverse order of removal.

Volkswagen B3 Passat Body Exterior

Window regulator, removing/installing: Power windows (Page 58-35-1)

Removing remove door trim panel, see Repair Group 70 unbolt glass from regulator push glass and secure fully upwards hold in place with tape remove bolts (arrows) and take out regulator Installing Reinstall all components in reverse order of removal.

Volkswagen B3 Passat Body Exterior

Door glass, removing/installing (Page 58-40-1)

Removing remove door trim panel lower window fully remove inner and outer trim plates remove guide rail 14 remove glass from window regulator

Installing Reinstall all components in reverse order, noting the following: if glass was removed from carrier, remount as shown a =384 mm (approximately 14.7 in.)

bolt glass to regulator do not fully tighten fully raise window, then lower until bolts are visible in holes (arrows) fully tighten bolts 7.0 Nm (5.2 ft lb)

Volkswagen B3 Passat Body Exterior

Outer window channel, removing/installing (Page 58-50-1)

Removing

remove inner/outer trim plates pull off inner window slot seal pull off outer window slot seal starting at upper corner, carefully snap (pry) off outer window channel from door flange as shown

Installing insert window channel in window slot (arrows 1) starting at upper corner, press channel downward onto door flange retaining clip (arrow 2) must engage fully reinstall all other components

Volkswagen B3 Passat Body Exterior

Impact bar, assembly (Page 58-60-1)

Note Impact bar is located under the protective molding A 1 - 25 Nm (18 ft lb) 2 - Washer 3 - Grommet 4 - Impact bar

Volkswagen B3 Passat Body Exterior

Door lock, assembly (Page 58-70-1)

1 - Lock knob screwed on lock rod A 2 - Inner door opening mechanism removing, see section 58-100 3 - Support 4 - Door handle removing installing, see section 58-80 reduce free play on door handle by turning adjuster 6 5 - Clamp 6 - Adjuster adjustable: reduces free play at door handle between adjuster and lock operating lever 17 = 0.1-1.0 mm (approximately 0.004-0.039 in.) adjusting: remove door handle or adjust from inside door if trim panel removed 7 - Screw w/washer 7.0 Nm (5.2 ft lb) 8 - 20 Nm (15 ft lb) 9 - Washer

collar faces away from C-pillar

Volkswagen B3 Passat Body Exterior

Door lock, assembly (Page 58-70-2)

10 - Plastic washer 11 - Striker bolt 50 Nm (37 ft lb) 12 - Door lock removing/installing, see section 58-90 if necessary, adjust free play between lock and door handle 13 - Seal must match door lock 14 - Locking lever 15 - Clip 16 - Pull rod insert into inner door opening mechanism from underneath 17 - Locking rod 18 - Pop rivet 19 - Locking lever

Volkswagen B3 Passat Body Exterior

Door handle, removing/installing (Page 58-80-1)

Removing

remove screw A push door handle in direction of arrow and pivot out of door Installing Reinstall all components in reverse order noting the following: check washer 2 and clip 3 for damage check 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

Door lock, removing/installing (Page 58-90-1)

Removing

insert screwdriver as shown, lock operating lever 4 remove sleeve from lock Installing Reinstall 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.)

Volkswagen B3 Passat Body Exterior

Inner door opening mechanism, removing/installing (Page 58-100-1)

Removing

insert screwdriver as shown, and pry out securing clip from hole in door panel push out inner door opening mechanism in direction of arrow Installing Reinstall all components in reverse order of removal.

Volkswagen B3 Passat Body Exterior

Door inner seal, removing/installing (Page 58-110-1)

Removing

remove door trim panel remove seal Installing Reinstall all components in reverse order of removal, noting the following; inner trim panel 1 fits onto seal as shown inner seal starts at point 2 a = 360 20 mm (14 3.0 in.)