Remove rear lock mechanism

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desertstorm
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Passat model: B5.5 130 TDI AWX
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Remove rear lock mechanism

Post by desertstorm » Sun Dec 30, 2012 10:06 pm

Had to replace a rear central locking motor the other day so took a few pictures.
First start on the inside of the car and undo the Torx screw at the bottom of the door panel.

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Then remove the cover on the door handle, there is a small flat hole to put a screwdriver in at the bottom of the cover.

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Undo the 2 phillips screws securing the handle.

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The only thing holding the interior trim panel now are several popper fasteners around the edge of the trim, these are around the left and right side and across the bottom. Using a wide flat blade screwdriver or similar tool undo these.
You can now take the connector off the puddle light at the bottom of the door panel.
The panel needs to be lifted now to release it from the top of the door. There are still wires attached to it for the speaker, electric window switch and the interior handle.These need to be removed before the trim panel can be put to one side.

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Moving to the end of the door by the lock itself, pull back the rubber and you will see a small torx screw that holds the lock blanking cap, Undo this but not all the way, when you feel it go loose screw it back in a turn or two to make sure it doesn't drop down into the door. You can undo the two spline bolts that hold the lock mechanism as well while you are here.

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The lock cover can now be removed by pulling the handle and when you pull on the cover it should come out. You can now see the cable that connects from the door handle to the lock.

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Take a note of where the cable is located and use a small screwdriver and flick the end of the cable from the serrated grooves in the handle.

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Going back to the door panel on the inside find the large round black cover just below the window motor and open it up. You will see a white plastic peg, assuming the window is wound all the way down, which it should be.

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This peg secures the window mechanism to the window through a hole at the bottom of the window glass. So bear this in mind when bashing away trying to knock the peg out. It is in two parts an inner pin and outer bush.
Use a small screwdriver to press the centre pin through, then use a larger screwdriver to push the outer bush through. These can be recovered from the bottom of the door when you remove the panel.

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Now you should be able to slide the glass up to the closed position by hand, I use some tape to hold it there.

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Now you just need to remove the brass colored 10mm bolts securing the inner steel skin and you can slide the skin out with the lock mechanism. Recover the pin and bush from the bottom of the door.

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Undo the electrical plug from the bottom of the lock mechanism. The operating cable for the interior handle has a rubber bung on it where it passes through the door, just push this through the skin to allow the rest of the cable to come through.
The door lock is held to the skin with 2 black plastic rivets. These are very easy to lose but a oh fiddlesticks! to push through. Put some kind of cup or something to catch the rivet on the inner side of the skin and push the rivet through from the lock side.
Once these two rivets are out you can loosen the lock from the door skin and then twisting it remove the rod that goes to the door locking button.

As they usually say to put it back together is a reversal of what you have just done.However a few things to be aware of.
Thanks to Passattdi130 for pointing the following out.
There is a particular way of getting the pin and bush back in the window.
The bush and pin are preassembled in the hole in the bottom of the glass, when the door skin is fitted and the glass is lowered gently the bush will be guided back to the hole in the window carrier and should locate itself.

http://elsaweb.spaghetticoder.org/doc/V ... 23616182/3

Karl.
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