57-1

Front door
Tools
Special tools and equipment T 10011 Socket 3320/2 Bit insert for 3320 3410 Socket T 10034 Assembly tool

57-2

Front door, assembly overview

Note: The instrument panel must be removed to remove and adjust the upper door hinges. Always replace the hinge bolts if loosened. 1 - Door Removing and installing 2 - Door handle with base Removing and installing 3 - Lock cylinder housing Removing 4 - Cover cap 5 - Bolt 18 Nm (13 ft lb) 6 - Locking button Removing and installing Page 57-23 Page 57-11 Page 57-12 Page 57-7

57-3

7 - Locking rod 8 - Boot 9 - Bolt 20 Nm (15 ft lb) 10 - Lock plate 11 - Door lock Removing and installing 12 - Bowden cable 13 - Interior release handle 14 - Multi-point socket head bolt M8 x 28 20 Nm (15 ft lb) + 1/4 turn further (90 ) Always replace bolt after loosening Page 57-15

57-4

15 - Multi-point socket head bolt M8 x 28 Only remove this bolt from hinge to remove door 20 Nm (15 ft lb) + 1/4 turn further (90 ) Always replace bolt after loosening 16 - Door hinge with arrester Hinge is divided 17 - Multi-point socket head bolt M8 x 28 Install from inside vehicle Remove A-pillar lower trim Repair Manual, Body Interior, Repair Group 70 20 Nm (15 ft lb) + 1/4 turn further (90 ) Always replace bolt after loosening

57-5

18 - Multi-point socket head bolt M8 x 28 20 Nm (15 ft lb) + 1/4 turn further (90 ) Always replace bolt after loosening 19 - Multi-point socket head bolt M8 x 28 20 Nm (15 ft lb) + 1/4 turn further (90 ) Always replace bolt after loosening 20 - Cover cap 21 - Bolt 13 Nm (10 ft lb) 22 - Door hinge Hinge is divided

57-6

23 - Multi-point socket head bolt M8 x 22 Install from inside vehicle To loosen or tighten bolt, remove and install instrument panel Repair Manual, Body Interior, Repair Group 70 20 Nm (15 ft lb) + 1/4 turn further (90 ) Always replace bolt after loosening 24 - Multi-point socket head bolt M8 x 28 20 Nm (15 ft lb) + 1/4 turn further (90 ) Always replace bolt after loosening

57-7

Door, removing and installing

- Remove A-pillar lower trim -5Repair Manual, Body Interior, Repair Group 70 - Disconnect wiring connectors -6- on A-pillar. - Pull boot -3- off A-pillar. - Guide electrical wiring out of pillar through hole (arrow). - Pry off cover cap -2- and remove bolt -1- from upper hinge pin. Tightening torque: 13 Nm (10 ft lb) - Remove lower bolt -4- from hinge using tool 3320 and bit insert 3320/2. Tightening torque: 20 Nm (15 ft lb) + 1/4 turn further (90 ). Note: Always replace this bolt. - Lift door upward out of door brackets.

57-8

Door, adjusting
Door adjustment requires that the door hinges on the pillar must be loosened. Other measures such as raising the door upward have no effect. Excess pressure thereafter will again cause the door to sag. Use door adjustment wrench 3320 with bit insert 3320/2 to adjust the door. To loosen the door hinge on the upper A-pillar from the interior, use socket 3410. The instrument panel must be removed for this procedure.

Repair Manual, Body Interior, Repair Group 70

57-9

Door handle and lock, assembly overview

1 - Door lock The door lock can only be removed in conjunction with the assembly carrier. Removing and installing 2 - Cable Lock release 3 - Retaining bracket Bolted and riveted to door lock Not supplied with door lock 4 - Handle bracket Removing: Door handle, lock cylinder housing and assembly carrier are removed - Remove screw - 5 -, slide bracket slightly to rear and remove from door. Page 57-15

57-10

5 - Screw 6 - Door handle with base Removing and installing 7 - Cover cap 8 - Lock cylinder housing Removing Page 57-11 Page 57-12

Lock cylinder is not supplied as individual part 9 - Backing 10 - Multi-point socket head bolt Use socket insert T 10011 Loosening releases lock cylinder housing - 8 -, which can then be removed from bracket - 4 Bolt must not be threaded in without lock cylinder housing installed or locking ring may fall into door.

57-11

Lock cylinder housing, removing

- Pry out cover cap -3-.

- Pull door handle -1- and hold. Loosen bolt -3- onto stop with socket insert T 10011 to release lock cylinder housing. Note: Loosening the bolt too far may result in the locking ring releasing from the handle bracket and falling into the door. - Pull lock cylinder housing -2- out of handle bracket at right angles.

57-12

Door handle, removing and installing

Removing lock cylinder housing Removing - Unclip clip -1- from door handle. - Swing door handle -2- out of door. Page 57-11 .

57-13

Installing - Place assembly tool T 10034 through hole of door sheet metal. - Using a flashlight to view door interior, hook assembly tool in spring -1- (arrow -A-). - Hang spring up into door lock by pulling assembly tool (arrow -3-).

57-14

- Swing door handle into door. - Pull clip -1- into panel cut out and engage in door handle -2-. Note: When assembling clip, do not pull lock operating lever -3- and press door handle 2- onto door panel. - Check door handle function. An incorrectly installed and adjusted bowden cable cannot open door.

57-15

Door lock, removing and installing

The window regulators, the door lock and the loudspeaker are secured to the door assembly carrier. The door lock can only be removed in conjunction with the assembly carrier. The assembly carrier can only be removed when the door window clamping brackets of the window regulator are unscrewed. This is accomplished by lowering the door window to the height of the holes in assembly carrier and loosen the clamping brackets. If power windows cannot be lowered then the cause must be determined. Check the comfort locking system Diagnostic Trouble Code memory (address word 46) with the VAG 1551 scan tool.

Repair Manual, Body On Board Diagnostic (OBD), Repair Group 01 If an electrical malfunction is present it must be corrected first. If it is determined that a window motor is the

cause, then proceed as described on 57-17 .

Page

57-16

Removing - Remove front door trim.

Repair Manual, Body Interior, Repair Group 70

- Removing lock cylinder housing 11 . - Unclip clip -1- from door handle.

Page 57-

- Pry out cover cap -1-.

57-17

- Lower door window until door window securing bolts are accessible. Note: If the work sequence cannot be carried out because there is a malfunction with the power window motor, remove the motor to slide window down. - Loosen bolts -2- and press clamps apart. - Push window upward and secure in position (e.g. with tape).

- Disconnect all wiring connectors (arrows).

57-18

- Remove bolts -2-. Tightening torque: 20 Nm (15 ft lb).

- Remove bolts (arrows). Pull top of assembly carrier off of door, lift and take out of door toward hinges. - Turn assembly carrier and pull off connection to door lock. - Unclip electrical wiring on back of assembly carrier.

57-19

- Drive out clips -1- with a drift.

- Unclip cable -2- from clip -1-. - Pry door lock off assembly carrier using a screwdriver -3-. Note: The retaining bracket is not one of the items supplied with the door lock. The bracket is secured to the door lock with a bolt and a pop rivet.

57-20

- Unclip securing rod -1- by turning door lock in direction of arrow. - Unclip cable -2-. - Turn cable nipple through 90 and remove from eye.

57-21

Installing - Pull operating lever -1- in direction of arrow. - Tension spring -2- on door lock in direction of arrow with a screwdriver and hook notch on locking lever into spring. Note: Hooking the operating lever locks the mechanism. The incorrect attachment of the bowden cable later is thus prevented.

57-22

- Install assembly carrier in door. - Install all bolts. Tighten bolts marked -1- and -2- in prescribed sequence. Tightening torque: 8 Nm (70 in. lb). Note: The remaining bolts can be tightened in any sequence. - Press door window glass -3- into window guide (arrow) and tighten clamps with bolts -4- to 10 Nm (7 ft lb). Remaining installation is in reverse order of removal. - Perform functional check of door lock.

57-23

Locking knob for locking rod, removing and installing

The procedure for removing and installing the locking knob must be followed. Not observing the sequence may unscrew the locking rods in the front door locks and the relays in the rear doors or damage the mountings.

57-24

Removing Right front and left rear doors - Release locking knob by turning 180 counter-clockwise.

- Remove locking knob in upward direction. Installing Right front and left rear doors

- Install locking knob onto locking rod with mark (small dot on top) toward vehicle interior. - Press locking knob onto locking rod until fluted section of knob is flush with height of door trim. - Turn locking knob 180 counter-clockwise.

Locking knob in "locked" position can project approx. 0 - 2 mm above door trim.

57-25

Removing Left front and right rear doors - Release locking knob by turning 180 clockwise.

- Remove locking knob in upward direction. Installing Left front and right rear doors

- Install locking knob onto locking rod with mark (small dot on top) toward vehicle interior. - Press locking knob onto locking rod until fluted section of knob is flush with height of door trim. - Turn locking knob 180 clockwise.

Locking knob in "locked" position can project approx. 0 - 2 mm above door trim.

57-26

Door seals, assembly overview

1 - Door inner seal, 4-door Start at upper radius of door cut-out when installing seal 2 - Door inner seal, 2-door Start on B-pillar trim when installing seal 3 - Door inner seal 4 - Door outer seal, 4-door 5 - Clip Inserted into door seal

57-27

6 - Clip Inserted into door seal 7 - Door outer seal, 2-door Note: The trim must be removed to remove the door seals. It may be necessary to loosen the instrument panel to remove trim.