Volkswagen B3 Passat Body Exterior 55 Hood, lids (Page GR-55)

Transcription

1 55 Hood, lids (Page GR-55) Gas-filled strut discarding removing/installing Hood cable removing/installing Hood lock assembly Lock cylinder assembly assembly, w/central door locking Rear lid lock assembly, sedan assembly, wagon Rear lid tension spring mounting point Tailgate adjusting buffers

2 Hook lock, assembly (Page ) 1 - Hood release lever cable attached 2 - Screw self tapping/washer 3 - Sealing plug 4 - Clip 5 - Guide 6 - Clip, cable 7 - Cable replacing: unscrew at release lever and lock, unhook bowden cable from guides and pull out 8-12 Nm (8.9 ft lb) hex head, self-locking clean bolt and nut thread, coat bolt and nut threads with AM or equivalent before reinstalling 9 - Lock

3 cable attached

4 Hood cable, removing/installing (Page ) Removing open hood and support unscrew release lever and lock from cable attach string or wire approximately 1,000 mm (39 in.) long to cable end at release lever pull cable through from engine compartment side Installing attach cable to string or wire and pull through from inside car secure to hook lock and release lever

5 Rear lid lock, assembly: Sedan (Page ) 1 - Lock cylinder housing removing: remove trunk trim panel, press lugs 2 together, pull out housing vehicles with central locking, press slightly on plastic slide in slot with screwdriver, pull operating rod out of relay lever. 2 - Locking lugs 3 - Connector rod when installing rod 9, press relay lever against lock cylinder and clip connector rod in position (arrow) 4 - Connector, trunk light Nm (62 in lb) 6 - Striker plate Nm (62 in lb) 8 - Lock 9 - Pull rod 10 - Hex nut w/washer 6 Nm (53 in lb)

6 Rear lid lock, assembly: Wagon (Page ) 1 - Lock cylinder housing removing: remove tailgate trim panel, press lugs 2 together, pull out housing vehicles with central locking, press slightly on plastic slide in slot with screw driver, pull operating rod out of relay lever 2 - Locking lugs 3 - Connector rod when installing rod 5, press relay lever against lock cylinder and clip connector rod in position (arrow) 4 - Connector, luggage compartment light 5 - Pull rod 6 - Lock connect plug and clip in pull rod before screwing onto lock 7 - Screw, raised allen head 23 Nm (17 ft lb) 8 - Striker plate 9 - Screw, raised allen head, 23 Nm (17 ft lb) 10 - Hex nut w/washer 6 Nm (53 in lb)

7 Pull rod, adjusting: Wagon m.y. (Page ) Note The pull rod must be adjusted each time rear lid lock is disassembled or repaired. insert 3.2 mm (approx. 1/8 in.) drill 1 as shown pull rod in direction of arrow, until lever A inside lock touches drill insert pull rod into lock cylinder, and close hinge (arrow) remove drill check lock for proper function lever A inside lock must return to end position.

8 Lock cylinder, assembly (Page ) 1 - Lock cylinder housing, upper remove with lower part 2 - Lock cylinder removing: take off circlip and pull out cylinder with key inserted 3 - Seal 4 - Push button remove lower lock cylinder housing first 5 - Spring, push button remove lower lock cylinder housing first 6 - Retainer clips to tab A on upper housing 1 holds both housings together 7 - Lock cylinder housing, lower part removing: take off circlip 8, push retainer from tab A on upper housing Circlip

9 Lock cylinder, assembly: Vehicles with central door locking (Page ) 1 - Lock cylinder housing, upper remove with lower part 2 - Lock cylinder removing: drive out spring pin, remove eccentric do not lose ball 6, pull out cylinder with key inserted 3 - Seal 4 - Push button remove lower lock cylinder housing first 5 - Spring 6 - Ball coat with grease prior to installation 7 - Spring, push button remove lower lock cylinder housing first 8 - Retainer clips to tab A on upper housing 1 holds both housings together 9 - Lock cylinder housing, lower part

10 removing: drive out spring pin 10, remove eccentric 11, do not lose ball 6, push retainer 8 from tab A on upper housing 1

11 Lock cylinder, assembly: Vehicles with central door locking (Page ) 10 - Spring pin 11 - Eccentric remove carefully, take care not to lose ball Plastic slide contains removal slot for operating rod 13 - Operating rod removing: slightly press on plastic slide 12 in slot with screwdriver and pull out operating rod installing: insert operating rod until latches into plastic slide 12

12 Gas-filled strut, removing/installing: Wagon (Page ) Removing raise and support tailgate remove retaining clip 1 pry up retaining clip 2 with screwdriver if strut is to be reused, do not pull off retaining clip completely pull strut off ball stud Installing Reinstall all components in reverse order of removal.

13 Gas-filled strut, discarding: Wagon (Page ) Note After replacing gas-filled strut, gas should be released from unserviceable unit before discarding. WARNING! Never squeeze strut in vise in area other than shown. To do so can cause strut caps on either end to pop off and release spring, which is under high pressure. put on protective goggles clamp first 50 mm (2.0 in.) of strut cylinder in vise as shown "x" Note Cover area being cut open with rag to catch oil when it squirts out. using hack saw, cut cylinder open immediately to right of vise

14 Rear lid tension spring, mounting points: Sedan (Page ) Note Rear lid spring can only be removed and installed with special tool hole for spring

15 Tailgate buffers, adjusting: Wagon (Page ) 1 - threaded sleeve left hand thread 2 - spacer 3 - expanding clip with removing slot 4 - adjustment tabs 5 - slots for adjustment tabs 6 - slide 7 - lock bolt 8 - rubber buffer stop Adjusting raise tailgate insert small screwdriver in removing slot and pry out expanding clips 3 remove buffer using 3.0mm hex wrench, unscrew lock bolt 7 until flush with slide 6 adjust threaded sleeve 1 and check with 3.0mm hex wrench, as shown a = 3.0mm Note

16 New buffers are set to 3.0mm, and spacer 2 is set against threaded sleeve 1. pull out slide 6 until tabs 4 engage slots 5 b = 10mm (25/64 in) reinstall buffer with expanding clips lightly close tailgate

17 Tailgate buffers, adjusting: Wagon (Page ) raise tailgate and tighten lock bolt Nm (8.9 in. lb)