Passat - Rear Window Regulators Work Procedure
Ensure clean working conditionsOpen right rear door.
Cover rear seat with protective cloth.
Lower window.
Remove trim cover from door handle by using a small flathead screwdriver.
Remove upper and lower screws from handle. Remove handle.
Remove fastening screws holding door panel.
Remove electrical window switch by using a small screwdriver and slightly pressing down the plastic lock in back of the edge.
Pull out switch and disconnect from harness.
Remove door locking knob.
Remove three (3) screws securing holding tray.
Remove tray.
Loosen inside door latch handle/housing trim and remove.
Remove latch handle/housing.
NOTE:
Do not bend rod.
Remove rear triangle trim (leather interior vehicles only) by slightly pulling rear of trim to insert screwdriver to unlock clips.
Carefully pry up window rail moulding (arrow) together with door panel and remove door panel.
NOTE:
Put protective cloth underneath plastic tool or screwdriver. Do not use force - panel can break!
Close window.
Use plastic wedge tool from special tool kit, KL 3397, and block window from moving down.
Push in panel clip pins.
NOTE:
Clips will fall inside door and mug be retrieved.
Remove clips.
Completely remove sound absorber (shower curtain) and discard.
NOTE:
If outside temperature is below 50 degree, warm up adhesive area with a suitable heat blower prior to removing the sound absorber.
Remove lower door speed nuts and discard. Retrieve any loose material inside door.
Remove upper window regulator bolts.
Cut tie wrap holding electrical harness and discard.
Remove lower regulator bolt, holding regulator with hand. Do not let window regulator tilt (possibility of denting door shell).
Carefully pull down regulator toward lower door opening and remove regulator.
Move to workbench.
Use new replacement regulator, part number 357 839 462C, and transfer window regulator motor by:
Using rocking motion to carefully separate drive cable from motor.
Attaching new regulator to motor housing.
Removing plastic cover from regulator gear box.
Reinstalling metal cover plate, with gasket.
Cutting tie wraps securing the drive cable.
If missing, installing plastic valve, part number 100 959 001, to vent hole of motor.
Carefully guide new regulator assembly into door, hold with one hand into position.
Reinstall 6 mm bolts - lower one first - to secure regulator.
Attach regulator switch and move regulator attachment plate upward to align holes for window bracket.
NOTE:
Window bracket must be in back of regulator attachment plate.
Reinstall 6 mm bolts.
Tighten all securing bolts to 9 N-m.
Sequence: First the three motor bolts followed by the bolts for the guide.
Remove wedge tool holding window in position.
Operate window up and down a few times to ensure proper function. (Adjust by loosening and re-tightening guide bolts).
Use new tie wrap, part number N 020 902 2, to secure electrical switch harness. Ensure that harness has NO tension.
NOTE:
Tie wrap must OPEN loop so the harness can slide in loop.
Use new sound absorber, part number 357 867 202 A, and peel off upper half of protective plastic.
Guide door handle rod through sound absorber.
Carefully affix upper half to door, ensure tight fit and alignment with upper door panel clip holes.
Pull electrical switch harness through opening of lower sound absorber.
Completely pull-off protective plastic from sound absorber.
Pull sound absorber tight - front first and affix to door, properly lining up with door panel attachment holes.
Use roller from special tool kit, KL 3397, and roll over edges of sound absorber (adhesive area) to ensure tight fit.
Close door and rinse water down outside of window.
Check sound absorber for inside water leaks.
Reinstall panel clips and secure by pushing in pins.
Use new speed nuts, part number 357 868 143 and install by pushing through sound absorber material.
NOTE:
Do not damage sound absorber.