Solved: How to Replace Doors on Audi A4 and VW Passat?

Auto parts door removal.

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The procedure is as follows :----

Doors

REMOVAL & INSTALLATION
1990-97 Passat Models

Apply a protective layer of masking tape to the leading, lower and rear edges of the door and the rear edge of the front fender.

If desired, or on vehicles with electric windows, if disassembling the door, roll the window down before removing the door.

Disconnect the large hex shaped electrical connector on the lower A-pillar by turning it counterclockwise.

Remove the nut and threaded pin from the door check limiting strap bracket. Temporarily insert a small suitable flat blade screwdriver in place of the removed threaded pin, then close the door about ³ / ₄ closed and remove the screwdriver. This will allow the door check to be partially retracted and help to prevent from damaging the door jamb area.

Remove the small plastic cap on the lower portion of the upper and lower hinges.

Spray the set screw with a penetrating lubricant, then carefully seat the proper size hex tool and remove both the upper and lower set screws.

Spray a penetrating lubricant into the threaded area where the setscrews were removed and move the door from almost closed to open several times while alternately lifting the door slightly. This will help to loosen the hinges.

Carefully lift the door upward and separate the hinges.

Installation is in reverse order of removal noting the following:

Clean the threads of the hinges and the setscrew.

Apply a locking agent to the set screw and torque to: 57 inch lbs. (6.5 Nm).

Tighten the door check limiting strap nut and bolt to: 62 inch lbs. (7 Nm).

Lubricate the seal for the electrical multi-connector at the A-pillar with soft soap. Make sure the electrical connectors are fully seated before turning the lock ring. Turn the lock ring by hand until it can be felt to lock in place.

1998-00 Passat Models

Apply a protective layer of masking tape to the leading, lower and rear edges of the door and the rear edge of the front fender.

If desired, or on vehicles with electric windows, if disassembling the door, roll the window down before removing the door.

Disconnect the large hex shaped electrical connector on the lower A-pillar by turning it counterclockwise.

Remove the lower A-pillar interior trim to and disconnect the door wiring electrical connectors.

Remove the bellows and guide the wires out away from the door jamb.

Remove the protective cap on the upper hinge and remove the setscrew using a suitable hex tool.

Remove the lower hinge-to-door bolt.

Grasp the door firmly and lift upward to remove.

Installation is in reverse order of removal noting the following:

Install the setscrew and torque to 17 ft. lbs. (23 Nm).

Replace the lower hinge bolt and torque to:

Passat models:

Step 1: 15 ft. lbs.

Step 2: 90° ( ¹ / ₄ turn)

A4 models:

22 ft. lbs. (30 Nm)

ADJUSTMENT

The door alignment within the door opening in the body shell is adjusted my loosening the hinge bolts and moving the door as necessary. The door closure is adjusted by moving the latch pin or bracket.

The door hinges should be adjusted such that;

The door shell is level with the lower door jamb.

On front doors, the forward edge of the door is even with, or slightly recessed, not to exceed 0.040 inches (1mm), relative to the rear portion of the front fender.

On rear doors, the forward edge of the door is even with, or slightly recessed, not to exceed 0.040 inches (1mm), relative to the rear edge of the front doors, which can be accomplished by moving the hinges of the rear door or, by moving the striker pin or bracket of the front door if the front door closure is properly adjusted.

The closure of the doors is accomplished by moving the latch pin or bracket on the door pillar. The latch brackets are secured by 2 fasteners that are loosened to allow the bracket to be moved. The latch pin is adjusted by turning it counterclockwise to loosen it, moving it to the desired position and then tightening it. Use either a thin wall deep well socket or a boxed end wrench to loosen or tighten it.

Adjust the closure of the doors by loosening and moving the latch pin or bracket on the door pillar such that;

On front doors, with the door closed, the rear edge of the door is slightly above the leading edge of the rear door, not to exceed 0.040 inch (1mm). Note, if the door has a tendency to rattle over bumps, check and adjust the height of the latch pin or bracket as necessary.

On rear doors, with the door closed, the rear edge of the door is slightly above the adjoining body panel, not to exceed 0.040 inch (1mm). Note, if the door has a tendency to rattle over bumps, check and adjust the height of the latch pin or bracket as necessary.

On Audi A4 models the upper door window frame can be adjusted with the help of an assistant as follows;

Remove the door panel.

Loosen the 2 rear and the upper front fasteners that secure the window frame to the vehicle just enough the window frame can be moved, but tight enough to hold its position. Loosen the front lower fastener such that it is just touching the door shell.

NOTE

The front lower faster has a graduated wedge installed between the window frame and the door shell.

Have the assistant sit in the vehicle and firmly press upward on the upper window frame toward the roof and the A-pillar, while, from the outside the fit of the window carrier is observed, making sure it is properly seated, then have the assistant slide the graduated wedge as necessary to retain the position.

Open the door and tighten the window carrier-to-door shell mounting bolts to 22 ft. lbs. (30 Nm).

Close the door and recheck the adjustment. If necessary, repeat the adjustment procedures to attain the proper adjustment.

Once the adjustment is completed, reinstall the door panel.

Fig. The latch bracket shown is moved by loosening the mounting fasteners and sliding it as necessary. Matchmark the bracket to the door pillar before moving-1.8L Passat model shown

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This details will help you.

Thanks.

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For more car related problem troubleshooting:---

This are the sections, you can go through and click the link to read its troubleshooting.

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