Problem opening rear door

[peteekp]

I hope someone can help me to open my rear door, which will not open from inside or out, and has the child lock on.

I had a problem a few weeks ago - the sequence was this - I opened the rear door, I locked the car, I shut the rear door, but it didn't quite go all the way, then I pushed it hard to shut it the rest of the way. When I came back, I unlocked the car, and the door would not open.

I found this guide - N/S rear door won't open... HELP Plz (http://www.vwaudiforum.co.uk/forum/showthread.php?84254) which was very helpful indeed. I got into the door card, and pulled on the cable with a coathanger. The door worked perfectly after this, for about a week.

I have just been through the same process. However, I think that this time (it is admittedly very difficult to see), when I have got hold of the cable with the coathanger and pull, I can see the nipple (probably not the right word) at the end of the cable, which I guess is meant to be attached to the door handle - also explains why there is no resistance on the door handle. I guess my previous pull dislodged it slightly, and it has subsequently fallen off after a bit of usage.

I assume that I now need to take the inner door card (the big metal plate) off to get to the handle mechanism. I have been hunting high and low and cannot find out any instructions on this. I have got the plastic bit of the door card off. The inner, metal door card is just held on with a few bolts, but the bit that worries me is dismantling the window mechanism to get the inner door card off without instructions, in case I struggle to put it back. Do I just undo the three bolts holding the motor on? Will the window itself stay in place? Will it go back together without any problems? Can anyone offer any advice/guides/pictures?

Many thanks

Pete

[RichardSEL]

There's much in this forum on this. Search Bowden Cable. This runs betweeen the internal handle assembly and the lock mechanism. It has a collar on its end that slips out of its seating. There's a good access LHD thread, with good pix at:
DIY - Removing front door window, subframe, door lock, handle, window regulator, etc. (http://www.passatworld.com/forums/74-volkswagen-passat-b6-discussion/356505-diy-removing-front-door-window-subframe-door-lock-handle-window-regulator-etc.html)

As this question comes up often (and it hasn't yet happened on my '06MY) I've collected all the words of wisdom, video URLs, etc into a handy "cut out 'n keep" .doc file. PM me your e-mail address for a return with attach?

[peteekp]

Many thanks for the info. I tried to send you a PM last night, but apparently I have just noticed that I cannot do that until my post count is 10! Could you PM me your email, and I'll send you an email with my address?

I assume the process is basically the same for front or rear doors?

Much appreciated!

[DSG4ME]

It will be what Richard said,

Not sure if you will need to drill the door shield off or not, might be able to get to it without removing the armour.

http://www.vwaudiforum.co.uk/forum/showthread.php?61808-how-to-remove-rear-door-trim-panel (http://www.youtube.com/watch?v=Em0TMdrPiu4)


Re: Door card removal
I've just removed the rear drivers side door card (panel) today on my 06 Passat Estate. Quite an easy job;

1. Remove single screw at bottom centre of door panel using a torx screw driver head..

2. Pop off the cover to the door handle using a small flat head screwdriver..

3. There are then 6 plastic 'poppers' that hold the panel in place, 3 running up the front edge of the panel and 3 on the rear. I used an old plastic chopping board cut into long wedge shapes to start to prise the panel away. Starting at the rear bottom corner, insert wedge and use a torch to locate the exact position of the popper. Then use a flat point screwdriver to remove the popper. Be sure to prise out the poppers from where they fix into the door otherwise you will snap the mount in the door card that holds the poppers in place (as I did). Continue with the other 5.

4. Once all poppers are free lift the whole door card upwards and it will pop out at the top revealing a grove that the door card sits in. Supprt the door card.

5. Finally disconnect door lock cable, speaker and electic window cables..

Job done!

Refitting is just the reverse of the above making sure all poppers are located in the door card before installtion.