In progress: replacing the driver's side door lock actuator in my 2004 New Beetle 1.8T

Tools required for this job: triple square M4 and M8 bits, 10mm socket, and a beam type torque wrench

A set of triple squares I picked up from my local hardware store

The new door lock actuator

Here's the whole procedure from the Bentley Manual. Glass must be suspended with strong tape in order to remove the carrier assembly.

Hang on, how much torque?? (the metric unit is correct; they wrote ft-lb instead of in-lb.

First step to get the door lock cylinder out

Checking that the M8 bit fits.

remove the handle by unclipping the linkage cable from the actuator inside the door

Handle removed

Photo of the switches for the door lock (need to order another one, as this is beginning to wear out)

Window switches

Need to remove the plugs covering the bolts for the windows

Window carrier bolt. Loosen, then lift the window...

Window taped up in place. Nashua 557 duct tape FTW.

hood release lever out

Oops, broke the clip for the hood release lever. They don't sell this individually so I have to source one from a set.

Now I have to undo the window and door connectors

loosening the cover with body trim tools

loosen the boot

in context with the door

start pulling it out through the body

loosen the holder for the wiring guide

pry that out

keep pulling...

Now tape it all up to the carrier assembly

Now undo the carrier bolts. These must be removed in a specific de-torquing sequence (modified star pattern).

this black sealant crap is probably butyl tape; I'll have to clean it all off and reapply a new bead of it.

Door carrier assembly completely out. I'm going to install some sound dampening material in here later.

Yes, that's factory VW styrofoam...

Carrier assembly on the ground

Old door lock actuator

New one

scraping off the old sealant. I sprayed a tiny bit of WD-40 on it, and it melted clean off. Cleanup afterward was a cinch.