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Front Doors, Central Locking System Audi S6 C5

Door Locks & Anti-Theft Systems 4 illustrations ~2580 words

Front door and door component carrier, removing and installing

Note. The following list refers to (Scheme 1).

  1. Door component carrier NOTE: Before removing, mark the position of the door component carrier on the door using a fine felt-tip pen or equivalent. Removing: Remove door trim panel. See «FRONT DOOR TRIM, REMOVING AND INSTALLING»(/audi/s6/c5-1999-2004/remont/exteriorinterior-trim/#interior-trim__front-door-trim-removing-and-installing) . Disconnect harness connectors and unclip from door component carrier. Remove bolts -3-, -9-, -6- and -4- and lift door component carrier upward and out. Installing: Front door -5- must be adjusted before installing door component carrier. See «FRONT DOOR, ADJUSTING»(/audi/s6/c5-1999-2004/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__front-door-adjusting) . NOTE: Insert door component carrier into door, align with markings applied before removal and secure loosely. Install door component carrier and secure loosely with bolts -3-, -4-, -6- and -9-, and adjusting plates -2- and -7-. Shut door, check adjustment and readjust door component carrier as necessary. Repeat check and adjust if necessary. Adjusting. See «FRONT DOOR, ADJUSTING»(/audi/s6/c5-1999-2004/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__front-door-adjusting) . CAUTION: Tighten bolts in the specified sequence: -3-, -9-, -6- and -4-.
  2. Adjusting plate NOTE: The adjusting plate must always be installed. Inclination of front door at B-pillar can be adjusted by altering position of adjusting plate -2-. See «ADJUSTING DOOR COMPONENT CARRIER»(/audi/s6/c5-1999-2004/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__adjusting-door-component-carrier) .
  3. Bolt w/washer assembly 30 Nm (22 ft lb)
  4. Bolt w/washer assembly 30 Nm (22 ft lb)
  5. Front door NOTE: The door component carrier does not have to be dismantled in order to remove the front door. Remove bottom section of A-pillar trim. See «LOWER A-PILLAR TRIM, REMOVING AND INSTALLING»(/audi/s6/c5-1999-2004/remont/exteriorinterior-trim/#interior-trim__lower-a-pillar-trim-removing-and-installing) . Disconnect harness connectors at connection point on A-pillar. Unclip rubber boot between front door and A-pillar, and pull wiring harness and central locking wiring harness out from A-pillar. Remove T45 Torx (R) bolts securing upper and lower hinges to door (See «UPPER DOOR HINGE»(/audi/s6/c5-1999-2004/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__upper-door-hinge) and «LOWER DOOR HINGE»(/audi/s6/c5-1999-2004/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__lower-door-hinge) ) and remove door complete with door component carrier. Panel gaps. See «PANEL GAP DIMENSIONS»(/audi/s6/c5-1999-2004/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__panel-gap-dimensions) .
  6. Bolt w/washer assembly 30 Nm (22 ft lb)
  7. Adjusting plate NOTE: The adjusting plate must always be installed. The inclination of the door component carrier at the B-pillar can be adjusted by altering the position of adjusting plate -7-. See «ADJUSTING DOOR COMPONENT CARRIER»(/audi/s6/c5-1999-2004/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__adjusting-door-component-carrier) . If an adjustment plate has insufficient adjustment range, install a suitably sized washer. Do not use two adjusting plates together.
  8. Washer Self-adhesive
  9. Bolt w/washer assembly 30 Nm (22 ft lb)

Upper door hinge

Note. The following list refers to (Scheme 2).

  1. Bolt (installed from inside vehicle) (30 Nm or 22 ft lb)
  2. Upper door hinge
  3. Torx (R) bolt (30 Nm or 22 ft lb)
  4. Bolt (installed from inside vehicle) (30 Nm or 22 ft lb)
  5. Stud Tightening torque: 23 Nm (17 ft lb)
  6. Cap -6- for stud -5

Lower door hinge

Note. The following list refers to (Scheme 3).

  1. Lower door hinge
  2. Bolt (30 Nm or 22 ft lb)
  3. Front door
  4. Bolt (30 Nm or 22 ft lb)
  5. Torx (R) bolt (30 Nm, or 22 ft lb)

Window regulator and door window, removing and installing

Note. The following list refers to (Scheme 4).

  1. Door component carrier Removing and installing. See «FRONT DOOR AND DOOR COMPONENT CARRIER, REMOVING AND INSTALLING»(/audi/s6/c5-1999-2004/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__front-door-and-door-component-carrier) .
  2. Window regulator Door component carrier removed To remove, drill heads off pop rivets -5-, knock out rivet stems and detach window regulator. Shake door component carrier so that pop rivet stems fall out. To install, install rivets -5- in order (-a-, -b-, -c-, -d- and -e-) using VAG1753 pop rivet pliers. Note different rivets diameters
  3. Mount
  4. Torx (R) bolt 4.5 Nm (40 in. lb)
  5. Pop rivet Install rivets using VAG1753 pop rivet pliers in order: -a-, -b-, -c-, -d- and -e-. Diameter of rivets -a-, -b-, -c- and -d-: 4.8 mm Diameter of rivet -e-: 6.0 mm
  6. Door window Removing: Run window down to bottom position. Remove door component carrier. Before removing, mark longitudinal position of window at both mounts -3- using felt-tip pen. Remove bolts -4-. Lift window out of mount -3-. Installing: Install in reverse order of removal. Insert window into window regulator and align with markings applied before removing. Tighten bolts -4- to 4.5 Nm (40 in. lb). Installing a new window: Door component carrier removed To install, insert window into guide and push it back toward B-pillar as far as it will go. Move window upward as far as stop using window regulator without bolt -4-. Close mount -3- and tighten bolts -4- to 4.5 Nm (40 in. lb).

Front door, adjusting

Note. The rear door shell must first be adjusted if it has not been already. Panel gaps can be checked using 3371 adjustment gauge.

Panel gap dimensions

Dimension -A- = 3 mm +1 / -0 mm (0.118 in. +0.039 / -0 in.)

Dimension -B- = 4.5 mm +/- 0.5 mm (0.177 in. +/- 0.019 in.)

Dimension -C- = 3.5 mm +/- 0.5 mm (0.138 in. +/-0.019 in.)

Scheme 1

Scheme 1: Panel gap dimensions
Scheme 1: Panel gap dimensions

Adjusting door longitudinally

  1. Door hinge
  2. A-pillar
  3. Door
  1. Adjust door longitudinally by loosening hinge bolts (arrows -A-) on A-pillar at upper and/or lower door hinge and moving door -2- in elongated holes in hinge on A-pillar. Tightening torque: 30 Nm (22 ft lb)

Note. The illustration shows the lower door hinge.

Adjusting door flush with contour of body

Note. The following list refers to see scheme 6.

  1. Adjust door inward or outward by loosening upper and/or lower door hinge bolts (arrows -B-) and moving door within elongated holes in hinge. Tightening torque: 30 Nm (22 ft lb)

Note. Adjust the rear end of the door by altering the position of the striker plate inward or outward. See ADJUSTING DOOR AT STRIKER PLATE .

Adjusting door at striker plate

  1. Loosen bolts -2-.
  2. Move striker plate -1- until door shell is flush with contour of body.
  3. Tighten bolts. Tightening torque: 20 Nm (15 ft lb)

Note. Use this adjustment only to align the door inward or outward, not vertically.

Adjusting door component carrier

  1. Front door shell must be adjusted before adjusting door component carrier.
  1. Remove door trim panel.
  2. Align door component carrier by altering position of adjusting plate at bottom of door as shown. See item 5 in «FRONT DOOR AND DOOR COMPONENT CARRIER, REMOVING AND INSTALLING»(/audi/s6/c5-1999-2004/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__front-door-and-door-component-carrier) . The sealing lip -2- must conform to contour of A-pillar and roof frame.
  3. Adjust height of door component carrier first.
  4. If height adjustment is correct, loosen securing bolts at bottom of door component carrier and press door component carrier in toward center of vehicle.
  5. When pressing door component carrier -1- toward center of vehicle, push in slightly further to make allowance for restoring (outward) force of rubber seal.
  6. Position adjusting plate at B-pillar as necessary.
  7. Tighten lower securing bolts to 30 Nm (22 ft lb).

Note. Check the adjustment using a distance gauge. See MAKING DISTANCE GAUGE . Item -3- is the door glass.

Making distance gauge

  1. Make distance gauge according to specified dimensions using suitable material (for example, plastic or plywood). Dimension -a- = 3.7 mm (0.146 in.) Dimension -b- = 28.2 mm (1.110 in.) If the door component carrier is correctly adjusted, the gauge should contact the door window and the roof trim molding when applied at a point approx. 100 mm (3.94 in.) from the B-pillar.

Window regulator motor, removing and installing

  1. Door trim and door component carrier removed

Note. The window regulator motor can be installed or removed with the motor and the door window in any position. After installing the electric motor and wiring, turn the ignition on and off. Run the door window up to the top position (fully closed) and hold the window regulator switch for about 2 seconds. The window regulator is now in the basic setting and the "one-touch" opening/closing function is activated.

  1. Remove Torx (R) bolts (arrows) and remove electric motor. Tightening torque: 6.5 Nm (58 in. lb)

Front door handle and door lock, assembly overview

Note. The following list refers to see scheme 11.

  1. Door handle mount Releasing. See «RELEASING DOOR HANDLE MOUNT»(/audi/s6/c5-1999-2004/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__releasing-door-handle-mount) .
  2. Lock cylinder Before removing, remove door handle. See «DOOR HANDLE, REMOVING»(/audi/s6/c5-1999-2004/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__door-handle-removing) .
  3. Fulcrum lever
  4. Door handle Removing. See «DOOR HANDLE, REMOVING»(/audi/s6/c5-1999-2004/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__door-handle-removing) .
  5. Door lock Disengage operating rod -8- from fulcrum lever -3- prior to removing door lock. To remove, remove socket-head bolts -6- and remove door lock out downward.
  6. Socket-head bolt (M8) 20 Nm (15 ft lb)
  7. Locating pin For securing door lock in "zero" position (only installed on replacement part) After installing door lock and installing operating rod -8-, remove locating pin.
  8. Operating rod To remove door lock, disengage operating rod from fulcrum lever -3-.
  9. Operating rod (door lock)

Door lock, removing and installing

  1. Remove door trim panel.
  2. Run door window up to top position.
  3. Disconnect harness connector for central locking at door lock.

Note. When reinstalling the door lock, disengage operating rod -3- at the clip of the fulcrum lever (arrow). When installing a new door lock, disengage operating rod -3- at sliding sleeve -5-.

  1. Disengage operating rod -3-.
  2. Remove combination bolts -1- and remove door lock -2- in downward direction, between door component carrier and front door shell.
  3. Install in reverse order of removal.

Door handle, removing

Note. The following list refers to see scheme 13.

  1. Door handle
  2. Clip When disassembling door handle -1-, disengage operating rod -3-.
  3. Operating rod Before removing door handle, disengage operating rod at clip -2-. After installing new door lock, insert operating rod into sliding sleeve and lock operating rod in place. Remove locating pin -5- out of door lock.
  4. Sliding sleeve To lock operating rod -3- in place, push up sliding sleeve -4
  5. Locating pin Only installed on replacement part After installing operating rod -3-, pull out locating pin.
  6. Door lock Removing. See «DOOR LOCK, REMOVING AND INSTALLING»(/audi/s6/c5-1999-2004/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__door-lock-removing-and-installing) .

Auxiliary tool

Note. For easier disassembly and assembly, make up an auxiliary tool from welding wire as shown.

Dimension -a- = 300 mm (11.8 in.)

Dimension -b- = 20 mm (0.79 in.)

Dimension -c- = 10 mm (0.39 in.)

Dimension -d- = 10 mm (0.39 in.)

Scheme 2

Scheme 2: Auxiliary tool
Scheme 2: Auxiliary tool

Note. The door handle is shown removed to clarify the illustration.

Scheme 3

Scheme 3: Procedure
Scheme 3: Procedure
  1. Remove door trim panel.
  2. Run door window up to top position.
  3. Hook auxiliary tool -3- around fulcrum lever -1- as shown and partially pull out locking pin -2- in direction of arrow -A-.
  4. Using auxiliary tool -3-, pull locking pin -2- completely out of fulcrum lever -1- in direction of arrow -A-. see scheme 16
  5. Pivot fulcrum lever -1- upward.
  6. Using small screwdriver, disengage retainer for slide (arrow -B-) by lifting it slightly.
  7. Disengage slide -4- in direction of arrow -C-. See. see scheme 16.
  8. Remove door handle together with lock cylinder outward.
  9. Remove door handle mount inward.
  10. Install in reverse order of removal.
  11. Once door handle is inserted and locked in place in mount, use auxiliary tool to push in locking pin -2- in direction of arrow.
  12. Spring clip (arrow -B-) on locking pin -2- must fully lock home around fulcrum lever -1-. Peened rivet (arrow -A-).

Releasing door handle mount

  1. Using small screwdriver, disengage retainer for slide (arrow -A-) by lifting it slightly.
  2. Using offset open-end wrench (17 mm), release slide -3- of mount -2- in direction of arrow -B-.

Removing trim panel

  1. To remove, pull up door handle -2-, use small screwdriver to push out retainer -1- and remove trim -3-.

Front door handle, preassembling

Note. Replacement door handles must be painted and pre-assembled prior to installation.

Note. The following list refers to see scheme 21.

  1. Door handle To assemble: Insert spring -4- into mount. Insert door handle into mount -3- and push on fulcrum lever -8-. Push in pivot pins -5- and -6- and peen with center punch. See «PEENING PIVOT PINS»(/audi/s6/c5-1999-2004/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__peening-pivot-pins) . Install spring -4-. See «CORRECT INSTALLATION POSITION OF SPRING»(/audi/s6/c5-1999-2004/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__correct-installation-position-of-spring) .
  2. Buffer Insert after painting
  3. Door handle mount
  4. Spring Installation position. See «CORRECT INSTALLATION POSITION OF SPRING»(/audi/s6/c5-1999-2004/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__correct-installation-position-of-spring) . Grease spring with G 052 745 A3
  5. Pivot pin Pay attention to different pin lengths Peening. See «PEENING PIVOT PINS»(/audi/s6/c5-1999-2004/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__peening-pivot-pins) .
  6. Pivot pin Pay attention to different pin lengths. Peening. See «PEENING PIVOT PINS»(/audi/s6/c5-1999-2004/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__peening-pivot-pins) .
  7. Clip
  8. Fulcrum lever
  9. Locking pin Installing. See «INSTALLING LOCKING PINS»(/audi/s6/c5-1999-2004/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__installing-locking-pins) .

Peening pivot pins

Note. Before peening the pivot pins, protect painted surfaces with a fabric-backed adhesive tape.

  1. Support pre-assembled door handle on solid surface (e.g. jaws of vice).
  2. Secure pivot pins against falling by creating a light center punch mark.
  3. After peening pivot pins, check fulcrum lever for freedom of movement.

Correct installation position of spring

2 - Pivot pin

  1. Install spring -1- as shown.
  2. Grease with G 052 745 A3.

Installing locking pins

Peened pivot pin (arrow -A-).

  1. Press in locking pin completely using auxiliary tool (made up in workshop).
  2. Spring clip on locking pin (arrow -B-) must fully lock home behind fulcrum lever.

Central locking system, servicing

  1. Unlike the previous system, which was pneumatically operated, the new generation central locking system operates using electric motors.
  2. The lock actuators in the doors are integrated in the lock and have 2 electric motors.
  3. The lock actuators cannot be replaced separately.
  4. The first electric motor locks the door and the second electric motor locks the interior door mechanism ("Safe" function).
  5. Locked doors can no longer be opened from inside the car.
  6. The lock actuators for the fuel filler flap and rear lid each have one electric motor, and can be replaced separately.
  7. After an accident involving activation of the airbag, the control module for central locking will unlock any active door locks.
  8. The control module for central locking is located inside a protective box in floor cavity beneath driver's seat and carpet, in front of floor pan crossmember.

Removing lock actuator for fuel filler flap

  1. Disconnect harness connector.
  2. Loosen screws -2-, push back lock actuator -1- and remove.

Scheme 4

Scheme 4
Scheme 4

Rear lid lock actuator, removing and installing

Note. The following list refers to see scheme 26.

  1. Release handle To remove, disengage locating hooks and pull out release handle
  2. Seal
  3. Lock actuator Removing: Tailgate trim removed Lock system removed Using screwdriver, press in and disengage locating hooks on left release handle -1- in direction of arrow -A-. Pull left release handle -1- downward out of handle mechanism -4-. Remove Phillips-head screws -B- and remove lock actuator.
  4. Handle mechanism Removing. See «REAR LID LOCK AND HANDLE MECHANISM, REMOVING AND INSTALLING»(/audi/s6/c5-1999-2004/remont/exterior-body-panels/#hood-lids__rear-lid-lock-and-handle-mechanism) .
  5. Lock cylinder Sealant is sprayed on

Door seal, removing and installing

  1. Before removing door seal, remove trim panels at top and bottom of A and B-pillars together with sill trim panel. See «UPPER A-PILLAR TRIM, REMOVING AND INSTALLING»(/audi/s6/c5-1999-2004/remont/exteriorinterior-trim/#interior-trim__upper-a-pillar-trim-removing-and-installing) , «LOWER A-PILLAR TRIM, REMOVING AND INSTALLING»(/audi/s6/c5-1999-2004/remont/exteriorinterior-trim/#interior-trim__lower-a-pillar-trim-removing-and-installing) , «UPPER B-PILLAR TRIM, REMOVING AND INSTALLING»(/audi/s6/c5-1999-2004/remont/exteriorinterior-trim/#interior-trim__upper-b-pillar-trim-removing-and-installing) and «LOWER B-PILLAR TRIM, REMOVING AND INSTALLING»(/audi/s6/c5-1999-2004/remont/exteriorinterior-trim/#interior-trim__lower-b-pillar-trim-removing-and-installing) .
  2. To remove, pull door seal off door flange.
  3. Install end of PVC lip onto flange at marking -X- (+/- 5 mm, or 0.197 in.) near B-pillar.
  4. To install, press door seal -1- onto door flange all around door opening.

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