Post on 02-Apr-2018
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Volkswagen B3 PassatBody Exterior55 Hood, l ids (Page GR-55)
Gas-filled strut
discarding
removing/installingHood cable
removing/installingHood lock
assemblyLock cylinder
assemblyassembly, w/central door locking
Rear lid lock
assembly, sedan
assembly, wagon
Rear lid tension spring
mounting pointTailgate
adjusting buffers
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Volkswagen B3 PassatBody ExteriorHook lock, assembly (Page 55-10-1)
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 guidesand pull out
8 - 12 Nm (8.9 ft lb)
hex head, self-locking
clean bolt and nut thread, coat bolt and nut threads withAM 197 000 01 orequivalent before reinstalling
9 - Lock
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cable attached
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Volkswagen B3 PassatBody ExteriorHood cable, removing/installing (Page 55-20-1)
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 releaselever
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
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Volkswagen B3 PassatBody ExteriorRear lid lock, assembly: Sedan (Page 55-30-1)
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 withscrewdriver, pull operating rod out of relay lever.
2 - Locking lugs
3 - Connector rodwhen installing rod 9, press relay lever against lock cylinder and clip connector rodin position (arrow)
4 - Connector, trunk light
5 - 7.0 Nm (62 in lb)
6 - Striker plate
7 - 7.0 Nm (62 in lb)
8 - Lock
9 - Pull rod
10 - Hex nut w/washer 6 Nm (53 in lb)
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Volkswagen B3 PassatBody ExteriorRear lid lock, assembly: Wagon (Page 55-40-1)
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 withscrew driver, pull operating rod out of relay lever
2 - Locking lugs
3 - Connector rodwhen installing rod 5, press relay lever against lock cylinder and clip connector rodin 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)
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Volkswagen B3 PassatBody ExteriorPull rod, adjusting: Wagon - 1991 m.y. (Page 55-45-1)
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 leverA inside lock touches drill
insert pull rod into lock cylinder, and close hinge (arrow)
remove drill
check lock for proper function
leverA inside lock must return to end position.
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Volkswagen B3 PassatBody ExteriorLock cylinder, assembly (Page 55-50-1)
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 tabA on upper housing 1holds both housings together
7 - Lock cylinder housing, lower part
removing: take off circlip 8, push retainer from tabA on upper housing 18 - Circlip
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Volkswagen B3 PassatBody ExteriorLock cylinder, assembly: Vehicles with central door locking (Page 55-60-1)
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 cylinderwith key inserted
3 - Seal4 - 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 tabA on upper housing 1 holds both housings together
9 - Lock cylinder housing, lower part
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removing: drive out spring pin 10, remove eccentric 11, do not lose ball 6, pushretainer 8 from tabA on upper housing 1
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Volkswagen B3 PassatBody ExteriorLock cylinder, assembly: Vehicles with central door locking (Page 55-60-2)
10 - Spring pin
11 - Eccentric
remove carefully, take care not to lose ball 6
12 - Plastic slide
contains removal slot for operating rod
13 - Operating rod
removing: slightly press on plastic slide 12 in slot with screwdriver and pull outoperating rod
installing: insert operating rod until latches into plastic slide 12
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Volkswagen B3 PassatBody ExteriorGas-fil led strut, removing/installing: Wagon (Page 55-70-1)
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.
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Volkswagen B3 PassatBody ExteriorGas-fil led st rut, discarding: Wagon (Page 55-80-1)
Note
After replacing gas-filled strut, gas should be released from unserviceable unit beforediscarding.
WARNING!
Never squeeze strut in vise in area other than shown. To do so can cause strut capson 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
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Volkswagen B3 PassatBody ExteriorRear lid tension spring, mounting points: Sedan (Page 55-90-1)
Note
Rear lid spring can only be removed and installed with special tool 3072
1 - hole for spring
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Volkswagen B3 PassatBody ExteriorTailgate buffers, adjusting: Wagon (Page 55-100-1)
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
Adjust ing
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
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New buffers are set to 3.0mm, and spacer2 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
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Volkswagen B3 PassatBody ExteriorTailgate buffers, adjusting: Wagon (Page 55-100-2)
raise tailgate and tighten lock bolt 7
1.0 Nm (8.9 in. lb)