Central Locking - Install Revised Vacuum Lines at PDI

Number: 93-06

Group: 57

Date: December 2, 1993

Subject:
Central Locking Vacuum Line Modification-
Required at P.D.I.

Models:
Golf III/Jetta III 1994 M.Y.

VWUS Service has identified a potential problem area in the central locking system which requires immediate attention during the Pre-delivery Process.

The vast majority of complaints received against the central locking system relate to plastic vacuum lines pulling loose from their rubber connecting hoses at the central connector plugs in the B-pillars. To correct this condition, replace these soft-rubber connecting hoses with a longer, reinforced version of vacuum hose.

Until further notice, perform the following procedure to both B-pillar connections on all 1994 Golf III and Jetta III vehicles prior to retail delivery:

^ Open a rear door. Pull back the rubber bellows between the door and the B-pillar to expose the central connector plug.

^ Unscrew and separate the outer portion of the central connector plug. This will expose the 1" long rubber connecting hose for the central locking vacuum lines to the rear door lock.

Grasp the connecting hose and carefully use it to pull a short section of the plastic vacuum line out of the B-pillar. Pull it just far enough so that you can reach into the central connector plug with needle nosed pliers and grasp the plastic line to hold it exposed.

^ Then pull the rubber connecting hose off this end of the plastic line and replace it with a 2" long piece of braided vacuum hose, part number N 020 353.5. Apply some trim adhesive to the plastic line before installing the braided hose (Do not clog lines with adhesive). This will act as a lubricant for installation, and an adhesive after curing. Make sure to insert the plastic line a full 1/2" into the braided hose.

Now pull the original rubber hose off of the plastic line from the door, and prepare to connect the other end of the new braided hose in its place. Before completing this connection, make sure that the hole through the central connector coupler is large enough to allow the new vacuum hose to slip completely through. On some vehicles this hole has a narrowed opening on one end, allowing only the plastic line through. On these vehicles, pull the plastic line out of the coupler and run an 8 mm drill bit through to open up the final 2 or 3 mm of this hole. Now complete the plastic line to braided hose connection, making sure to use trim adhesive and the same 1/2" insertion depth for the plastic line.

Reassemble the two halves of the central connector plug. Approximately 1" of the braided hose should protrude from the plug when assembled, for increased flexibility.

Reinstall the rubber bellows on the central connector plug and make sure none of the segments are stuck together. Lubricate the exterior of the bellows with silicone to ensure that the segments do not stick together after a duration of being held in a compressed position by the closed door.

Repeat the same modification procedure to the vacuum line connection on the other side of the vehicle.

Labor Operation: 5776510
Time Allowance: Repair: 25 T.U.
QC: 5 T.U.