desmontaje modulo puerta passat

8/15/2019 desmontaje modulo puerta passat

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HOW TO REMOVE YOUR DOOR LOCK MODULE

1. I had some free time and all the necessary pics, so I put this DIY

together. Hope it's useful to someone.

REPLACING THE FRONT DOOR WINDOW REGULATOR CLIPS

AND/OR DOOR LOCK MODULE The following DIY outlines the procedure for removing the window

regulator carrier panel, replacing the window regulator clips and the

door lock module on a !I" #etta $some steps may also apply to a

!I" %olf&%TI as well. The procedure was (ased on a )).* #etta %+

"- with power windows / it may (e slightly di0erent on later models

and on those with manual windows. lease do these procedures at

your own risk and (e ready to make small ad2ustments while doing

them. 3lso, please (e o(servant while removing parts so that they go

(ack together correctly.

The window regulator clips used in this DIY were purchased fromI45 and were part of a 6indow -egulator -epair !it. The kit comes

with four clips $two for the left door and two for the right door and

one ca(le&take/up reel assem(ly $only needs to (e used if the e7isting

ca(les are damaged / this part is not a redesigned&upgraded piece.

There are two versions of the kit, depending on which ca(le assem(ly

you need. "6 part8 1#/9)9/:1/3 comes with the ca(le assem(ly

for the left door and "6 part8 1#/9)9/:;/3 comes with the ca(le

assem(ly for the right door. The kit should cost esides

Impe7, you can also (uy a kit from the dealer, 4? Tuning or a

num(er of other online parts dealers.It may be po!b"e to #e$e!%e a #e&'() &o# t*e $ot o& b'y!(+

t*e W!()o, Re+'"ato# Repa!# K!t a() )o!(+ t*e #epa!#

yo'#e"&- A "o(+ a yo' )o t*e p#o$e $o##e$t"y. !t *o'")

a%e VW $o(!)e#ab"e t!me a() mo(ey a() !( ma(y $ae.

,o'") be !( t*e!# bet !(te#et to *a%e o,(e# )o t*e #epa!#

t*eme"%e- Im $'##e(t"y !( t*e p#o$e o& t#y!(+ to #e$e!%e a

#e&'() &o# t*e $"!p 0p'#$*ae) a&te# e1te()e) ,a##a(ty ,a

a((o'($e)2- I& I *a%e a(y "'$3. I"" pot t*e pe#t!(e(t

!(&o#mat!o( &o# #e$e!%!(+ a #e&'()-

The part8s for the lock modules are door speci@c and may also vary(etween model and year. ake sure you o(tain the correct parts for

your vehicle.

The tools needed to replace the window regulator clips and&or door

lock module are a Aat/head screwdriver, a hillips screwdriver, T;=

and TB= Tor7 drivers, a 1=mm socket $wrench or driver, an 9mm

triple sCuare tool, a rag, a sheet or (lanket and a roll of duct tape. 3

drill and a set of (its $not sure e7actly what sie (it can also (e used

during the procedure to disconnect the door lock module from the

carrier panel. Doing so reduces the num(er of steps necessary to

remove the carrier panel from the door $more detail on this is given

(elow. If you are replacing the door lock module and do not use the

drill to disconnect the door lock module from the carrier panel, you'll

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also need a small punch to push out the plastic rivets that secure the

door lock module to the carrier panel. This is the recommended

method since the rivets are not destroyed and can (e reused when

reinstalling the carrier panel on the door.

Einally, the procedure should take (etween 1 and B hours, depending

on e7perience. I have done the procedure $replacing the windowregulator clips four times and this most recent time it took me ;.*

hours, mostly (ecause I spent a lot of time taking pics and notes

a(out the procedure for this DIY. If I hadn't (een taking pics and

notes, it would have taken (etween 1 and 1.* hours.

(Note: The procedure below is for the front passenger's door

specically. The procedure for the driver's side door is nearly

identical, except that the parts are a mirror image of those of the

passenger's door. pecic di!erences between the passenger's and

driver's door (very few" will be mentioned in the text.

The procedure below assumes that the window clips have notcompletely failed and that the window still wor#s (moves up and

down with full range of motion". $f your clips have failed and the

window has fallen into the door, the procedure will be slightly

di!erent. $ will try to address these di!erences in the text.

%lso, a few of the pictures were ta#en on a previous occasion (when

the driver's door clips were replaced" so there may be slight

di!erences in the colors of parts and of the bac#grounds. &lease

ignore any continuity inconsistencies. $f you follow the procedure as

written using the pictures as a reference, you should not have any

problems completing the procedure."

FFFFFFFFFFFFFFFFFFFFFFFFFFFFFFFFFFFFFFFFFFFFFFFFFF FFFFFFFFFFFFFFFFFF

PART I 4 REMOVING THE WINDOW REGULATOR CARRIER PANEL

1. -emove the inner door trim panel $shown (elow using the

directions in the following DIY / -emoving front door parts.

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;. Gnce the panel is o0, you should see something like this. EYI, I

have aftermarket speakers, so your woofers will look di0erent if you

have stock speakers. 3lso, there is some Dynamat on my window

regulator carrier panel $the (lack panel (olted to the inside of the

door surrounding the woofer. This is not present on a stock panel.


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B. Disconnect the harness connector from the top of the woofer. The

appro7imate location of the connector on a stock woofer is shown

(elow.


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:. Disconnect the harness connectors for the tweeter and side/view

mirror, indicated (y the red arrows in the picture (elow.


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*. -emove the harnesses from the harness carrier $indicated (y the

yellow arrow, as shown (elow.

. sing a screwdriver, unplug the two ru((er grommets that coverthe access holes for the window regulator clips. Gne of the grommets


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is shown (elow.

. If your window still works $i.e., the clips have not completely (roken

and the window still moves up and down, continue on with step 9through 11 and then go directly to step 1B $skip step 1;. If your

window has fallen into the door, go directly to step 1;.

9. Depending on the current position of the window, raise&lower the

window so that the window regulator clips at the (ottom of the

window can (e seen through the access holes, as shown (elow. ince

the door panel is o0, you'll need to use the window controls on the

'other' door to do this.


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). The ne7t step is to temporarily support the window glass while the

regulator clips are (eing changed. lace a rag over the top of the

door. 3pply a piece of duct tape to the outside of the window, up and

over the top of the door and then to the inside of the window. I

recommend doing this diagonally with two opposing pieces of tape, as

shown (elow.


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ATTENTION5 P"eae ma3e '#e to $omp"ete"y e$'#e t*e

,!()o, ,!t* t*e )'$t tape- T*e #emo%a" o& t*e ,!()o,

#e+'"ato# $a##!e# pa(e" #e6'!#e t*at t*e e(t!#e ,e!+*t o& t*e

,!()o, +"a be 'ppo#te) by t*e tape- Fo# t*! #eao(. I o("y

#e$omme() '!(+ )'$t tape- Ot*e# type o& tape may (ot be

ab"e to 'ppo#t t*e ,e!+*t o& t*e ,!()o, +"a- S!($e t*e,!()o, may *a%e to be 'ppo#te) by t*e tape &o# 748 *o'#

o# mo#e. pe#!o)!$a""y $*e$3 to ma3e '#e t*e tape ! *o")!(+

p#ope#"y a() ! (ot pee"!(+ a,ay om t*e +"a- I& t*!

o$$'#. t*e ,!()o, +"a may &a"" !(to t*e )oo# a() *atte#9

1=. -emove the 1=mm (olt that secures each window regulator clip

$two total to the window glass, as shown (elow. If you are only

replacing the door lock module $i.e., not replacing the clips, you do

not need to remove the (olt, only loosen it.


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11. +ower the window regulator clips appro7imately :/J using the

window controls on the 'other' door. The clips should disconnect from

the (ottom of the window / this will help in removing the carrier panel

later on. %o directly to step 1B $skip step 1;.

1;. If the regulator clips fail and the window falls into the door, it can

(e diKcult to remove the carrier panel since the window often 'gets inthe way'. If possi(le, try to remove the window from the door

completely. This almost de@nitely reCuires the help of a second

person. 3ttempt to pull the window up (y its top edge. If you can

raise the window nearly out of the door, it pro(a(ly means that (oth

clips have de@nitely failed. Try to raise the window so that the clips

can (e seen through the access holes descri(ed in step 9. If this is

possi(le, remove the 1=mm (olts, as descri(ed in step 1= and slide

the clips o0. Gnce the clips are o0, remove the window from the door

(y pulling it up and out of the door. This is easiest if you rotate the

rear edge out @rst and pivot the window around the lower front cornertoward the front of the car. The window should come out of the door

easily. If you're successful in doing this, put the window aside in a

safe place. If you are not a(le to remove the window from the door

$(ecause it wasn't possi(le, not (ecause you didn't try, it may mean

that one of the regulator clips is still fully or partially intact. If this is

the case, you may have to improvise a little during later steps to

remove the carrier panel. I can't (e more speci@c a(out this pro(lem,

since each di0erent situation will have it's own solution.

ATTENTION5 P"eae be e1t#eme"y $a#e&'" ,*e( #emo%!(+ t*e

,!()o, +"a om t*e )oo#- Ma3e '#e to *a%e a t#o(+ +#!po( t*e +"a at a"" t!me o# !t may &a"" a() b#ea3-


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1B. Disconnect the harness connector from the regulator motor (y

pulling down on the retaining slide, as shown (elow.

1:. 3s you pull down on the retaining slide, the harness connector willslide toward the front of the car and o0 of the regulator motor, as

shown (elow.


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1*. ?heck to see if the door lock module is riveted to the carrier

panel, as shown in the picture (elow. Lormally, the lock module is

riveted to the panel, (ut if your regulator clips have (een replaced

already, the rivets may not (e present. "6 techs are notorious for not

reinstalling the rivets when replacing the regulator clips. If your lock

module is not riveted to the panel, perform step 1. If your lockmodule is riveted to the panel, you have two options. You can $1 drill

out the rivets and continue on with step 1 or you can $; leave the

rivets intact and go directly to step 1. Gption ; is the preferred

method since the rivets can (e reused when reinstalling the carrier

panel on the door / new rivets will not need to (e purchased. If you

plan on replacing the door lock module, you must perform all of the

related steps $1 through ;: / do not skip any of these steps.


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1. op o0 the ru((er grommets for the inner door handle release

ca(le and the door lock pin $indicated (y the yellow arrows in the

picture (elow and then push the grommets through their respective

holes in the carrier panel. 3fter doing this, go directly to step ;* / do

not perform steps 1/;: unless you are replacing the door lock

module. If you are replacing the door lock module, you MUST continue on with step 1.


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1. -emove the small plastic ta( on the rear edge of the door with a

screwdriver. The ta( is indicated (y the yellow arrow in the picture

(elow.


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19. >ehind the plastic ta( is a retaining screw which is used to secure

the (lank in the door handle, indicated (y the yellow arrow in the

picture (elow. Gn the driver's side door, the screw secures the piece

which surrounds the door lock key slot.


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1). +oosen $(ut do not completely remove the retaining screw with a

T;= Tor7 driver. The screw actually has a very small triple sCuare

head, (ut a T;= driver works perfectly. The retaining screw can (e

seen in the picture (elow.


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;=. +oosen the retaining screw enough so that the handle (lank slides

out of the door. The passenger's and driver's side pieces can (e seen

in the pictures (elow. Gn my car, the screws needed to (e turned

appro7imately 1B/1* turns for the pieces to slide out. 3lso, you may

need to pull out on the door handle slightly to allow each piece to

slide completely out.


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;1. The outer handle is connected to the door lock module (y a small

ca(le $red arrow in picture (elow. The end of the ca(le is secured to

the handle (y a small plastic ta( $yellow arrow in picture (elow which

@ts into a threaded groove.


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;;. op the ta( on the end of the ca(le out of its retaining groove

using a small screwdriver, as shown (elow. >efore doing this, note the

position of the ta( in the groove so that it can (e reinstalled in

appro7imately the same position later.

;B. The picture (elow shows the ta( detached from the retaining

groove.


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;:. -emove the two door lock module (olts on the rear edge of the

door using the 9mm triple sCuare tool. The (olts are indicated (y the

yellow arrows in the picture (elow. The 9mm triple sCuare tool is also

shown (elow.


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;*. op o0 the ru((er grommet and push in the wire loom retaining

clip indicated (y the yellow arrows in the picture (elow.

;. The grommet and retaining clip should look like they do in the

picture (elow when step ;* is completed.


23/57

;. ut a sheet or (lanket on the ground (elow the door and over the

door sill $as shown (elow to protect the sill and carrier panel when

the panel is removed from the door.

;9. -emove the ten $1= 1=mm (olts that secure the carrier panel to


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the door. The locations of the (olts are indicated (y the yellow arrows

in the picture (elow.

;). tarting at the rear (ottom corner of the panel, pull the (ottom ofthe panel away from the door slightly, as shown (elow. You may have

to move the panel up or down slightly to wiggle the (ottom of the

panel out of the door. This step may (e very diKcult to perform if the

window glass is still sitting at the (ottom of the door, especially if one

of the regulator clips is still attached to the (ottom of the window. If

this is the case, then this is the point in the DIY that you might have

to (e creative in order to complete the removal of the carrier panel

from the door.


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B=. 6hile holding the (ottom of the panel away from the door $and

also supporting its weight, reach (ehind the panel from (elow and

push the si7 $ wire loom retaining clips out of the panel. The

locations of the clips are indicated (y the yellow arrows in the picture

(elow. If you yank on the clips from the front of the panel, you will

almost surely damage them, making it diKcult to reattach them whenreinstalling the panel.


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B1. 3 close/up of one of the wire loom retaining clips is shown (elow.

The clips are held in place (y small ta(s on opposite sides of the clip,

indicated (y the yellow arrows. ush in on these ta(s simultaneously

and push the clip out of the panel.


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B;. Gnce the ta(s are out, lift up on the panel slightly, pull the (ottom

of the panel away from the door, and then lower the panel toward the

ground and toward the front of the car. It is necessary to do this

(ecause the window tracks e7tend a(ove the top of the carrier panel

inside the door $(lue arrows in picture (elow and the door lock

module e7tends to the right of the panel inside the door $red arrow inpicture (elow. If you are removing the carrier panel with the door

lock module still (olted to the edge of the door, you do not need to

slide the carrier panel toward the front of the car when removing it

since the lock module is not attached and will not impede its motion.

You'll only need to lower the panel so that the window tracks clear.

3lso pay careful attention to the inner door handle ca(le and door

lock pin when removing the panel as they are attached to the door

lock module and must slide out of the panel.

BB. Gnce the panel is removed from the door, disconnect the harness

connector for the door lock module (y pressing down on the ta(

indicated (y the yellow arrow in the picture (elow and then sliding

the harness connector away from the lock module. $EYI, the lock

module on the driver's side door is shown in the picture (elow in case

someone notices some inconsistencies in the appearance of the

harness&lock module relative to the carrier panel.


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B:. ull the door lock module wire (unch $indicated (y the yellow

arrow in the picture (elow and harness connector through the hole in

the carrier panel. The panel should now (e completely disconnected

from the door.


29/57

B*. If you plan on replacing the window regulator clips, go directly to

art II $(elow.

If you plan on replacing the door lock module, go directly to art III

$(elow art II.

+et me know if you have any Cuestions.A a",ay. )o t*! p#o$e)'#e at yo'# o,( #!3- I am (ot

#epo(!b"e &o# a(y m!ta3e !( t*e p#o$e)'#e o# t*oe t*at

yo' ma3e ,*!"e pe#&o#m!(+ !t-

odied by g)t* at +:- & /0+/0-1

Rep"y W!t* :'ote

;.

B. V+Rt;

Mo)e#ato#

#oin Date

ar 9th, ;==;

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1,1;)

3-T II / -4+3?IL% TH4 6ILDG6 -4%+3TG- ?+I

=)/=9/;==B =)M*= 8;

PART II 4 REPLACING THE WINDOW REGULATOR CLIPS

teps 1 through * provide some (ackground info on how the old/design

window regulator clips (reak, the di0erences (etween the old/ and new/

design clips and how the window regulator assem(ly works. The actual

replacement of parts (egins with step .

1. 3n intact, old/design window regulator clip can (e seen in the picture

(elow. The old/design clips are a two part design / a metal clamp $which

attaches to the (ottom of the window glass which slides into a plasticsupport. The plastic support slides up and down the window regulator track

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via an +/groove $right angle in the support and is connected to a motor (y a

set of opposing ca(les / one moves the clip down the track and one moves it

up the track.

;. 3 (roken, old/design window regulator clip can (e seen in the picture

(elow. The old/design clip fails when the plastic support cracks and pieces

(reak o0. This allows the metal clamp portion of the clip to fall out of the

plastic support, often resulting in the window falling into the door $usually

when (oth clips fail. y original clips were replaced after :.* years. Gn (oth

the driver's and passenger's side doors, one of the two clips was found to (e

(roken when the window regulator carrier panel was removed. I have no

idea how long the clips were (roken and how much longer the remaining

intact clips would have lasted. I consider myself e7tremely lucky not to have

had a window fall into the door. Gnly closing the doors with the windowsfully closed $I was afraid of the clips (reaking pro(a(ly had something to do

with the clips lasting this long.


31/57

B. The di0erences (etween the old/ and new/design regulator clips can (e

seen in the picture (elow. 6hile the old clip is a two/piece metal&plastic

design, the new clip is a one/piece metal $pot metal design with a small

plastic +/groove sleeve insert to allow for easy sliding on the window track.

The new/design clip is considera(ly stronger than the old design and should

have (een used from the (eginning $would have saved "6 and itscustomers a illion headaches.


32/57

:. The coloried image (elow illustrates how the window regulator system

works. The window glass is raised up and down (y a set of clips $yellow that

attach to the (ottom of the glass. The clips are raised up and down (y a set

of opposing ca(les $(lue which travel around a set of pulleys $red and are

controlled (y a drive unit which consists of a ca(le take/up reel $green and

an electric motor $(ehind the take/up reel on the other side of the carrierpanel. The ca(le network is setup $uses a criss/cross pattern so that (oth

clips move up and down at the same time.


33/57

*. The coloried image (elow illustrates how the take/up reel unit works.

Inside the unit is a wheel $yellow which has the opposing ca(les $(lue and

red wrapped around it in opposite directions. Therefore, as the window

motor rotates the ca(le wheel, one ca(le is let out while the other is wound

in around the wheel. The springs on either end of the take/up reel unit

assure that the ca(les always remain tight $even when the clips fail and thewindow falls into the door and that the window operates smoothly.


34/57

. The replacement of the window regulator clips (egins with the

determination of whether or not the ca(le&take/up reel assem(ly supplied in

the 6indow -egulator -epair !it will also (e replaced. The ca(le&take/up reel

assem(ly is not an improved part / only the regulator clips have (een

redesigned. The ca(le&take/up reel assem(ly only needs to (e replaced if

the ca(le or take/up reel unit was damaged if&when the original clips (roke

and the window fell into the door. If your e7isting ca(les are G!, you do not

need to replace the ca(le&take/up reel assem(ly when replacing the

regulator clips.

. The ca(le&take/up reel assem(ly supplied with the 6indow -egulator

-epair !it can (e seen in the picture (elow. The take/up reel assem(ly

comes with a steel (racket attached which is used to keep the ad2usting

springs compressed while the assem(ly is not installed on the carrier panel.

This (racket makes it signi@cantly easier to replace the regulator clips and is

why "6 supplies it with the new ca(le&take/up reel assem(ly. It is still

possi(le to change the regulator clips without the (racket, (ut doing so

reCuires that the springs (e compressed manually while trying to reinstall

the regulator ca(les around the pulleys $this will make more sense later on.

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9. If you are replacing the ca(le&take/up reel assem(ly, leave the (racket in

place on the new assem(ly and go directly to step ). If you are not replacing

the ca(le&take/up reel assem(ly, remove the (racket from the new assem(ly

$(e very careful / the springs are under considera(le tension and slide it

onto the old ca(le&take/up reel assem(ly which is attached to the carrier

panel, as shown (elow. If you're doing this step, make sure that the (racket

is slid onto the old assem(ly completely. You don't want the (racket to

accidentally pop o0 the assem(ly when the tension is o0 the ca(les and the

ca(les are removed from the pulleys $this will also make more sense later

on. %o directly to step 1= $skip step ).


36/57

). -emove the regulator motor from the front side of the carrier panel $the

side opposite where the clips, ca(les, etc are so that the take/up reel unit

on the (ack side of the panel can (e removed. To do this, remove the three

$B TB= Tor7 screws indicated (y the yellow arrows in the picture (elow and

pull the motor assem(ly o0 of the carrier panel. Do NOT attempt to remove

the ca(le&take/up reel assem(ly o0 of the other side of the carrier panel atthis time.


37/57

1=. sing a screwdriver, pry the ca(le o0 of one of the pulleys on the carrier

panel, as shown (elow. The (ottom rear pulley $closest to the rear of the car

when the carrier panel is installed and closest to the ground is shown in the

picture (elow. Gnce the ca(le is removed from one of the pulleys, there

should no longer (e any tension on the ca(le and it can (e easily removed

from around the other pulleys. If you are replacing the ca(le&take/up reelassem(ly, remove the ca(le from the (ottom front and top rear pulleys only

/ the ca(le can (e left in place around the other two pulleys $top front and

(ottom rear. If you are not replacing the ca(le&take/up reel assem(ly, you

only need to remove the ca(le from one of the pulleys / it doesn't matter

which one you choose. Note5 It will (e more diKcult to remove the ca(le

from the @rst pulley with the screwdriver if you are planning on replacing the

ca(le&take/up reel assem(ly and did not slide the steel spring (racket o0 of

the new ca(le&take/up reel assem(ly and onto the old assem(ly.


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11. teps 1; through ;; deal with the removal of the old/design clips and

the installation of the new/design clips. I -4?G4LD that you remove and

reinstall each clip completely (efore attempting to remove and reinstall the

other clip $i.e, perform steps 1; through ;; on only one clip at a time. It's

possi(le to do the procedure on (oth clips at the same time, (ut doing it on

only one will help insure that the ca(le routings remain in the correct

position, something that may save some time when the ca(les need to (e

reinstalled on the pulleys. Note5 If you are also replacing the ca(le&take/up

reel assem(ly, you MUST remove (oth clips from their ca(les so that the

ca(le&take/up reel assem(ly can (e replaced.

1;. The schematic (elow shows a cross/section of a new/design clip in place

on the window track $the old/design clip attaches to the track in e7actly the

same way / the only di0erence in the schematic would (e the design of the

clip itself. The schematic clearly shows how the window track @ts into an +/

groove in the clip (ody $on the new/design clip, the +/groove is in a plastic

sleeve that is an insert in the clip (ody, as shown (elow.


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1B. To remove the old clip from the window track, rotate the clip (ody away

from the window track $3 and then slide the clip o0 of the track $>, as

shown in the schematics (elow. In some cases, the carrier panel itself may

interfere with the rotation of the clip illustrated in schematic $3. You may

need to slide the clip up or down the window track $depending on which clip

and which pulley the ca(le was removed from to an area where rotation isunimpeded. If this is not possi(le, you may need to remove the ca(le from

another pulley to create some more slack in the ca(le. If it's still not possi(le

to remove the clips, you can always remove the ca(le from around all of the

pulleys / this should allow you to move the clips fully up or down the window

track.


40/57

1:. The picture (elow shows a side view of an old/design clip (ody where

the ca(les attach $actually one of the (roken clips. The ca(les @t into

grooves on the underside of the clip (ody. Gne of the grooves is deeper than

the other / the ca(le in the deeper groove needs to (e removed last andinstalled @rst.


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1*. 3 picture of the underside of the clip (ody $(elow shows how the ca(les

are secured in the (ody. There is a small ca(le stop on the end of each ca(lewhich @ts into a hole on the underside of the clip (ody.


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1. To remove the ca(le ends from the clip (ody, remove the ca(le from its

groove $start with the ca(le in the more shallow groove and rotate the

ca(le around the stop until the ca(le is roughly perpendicular to the clip

(ody, as shown (elow. Then simply pull the ca(le stop out of the clip (ody.


43/57

1. If you are replacing the ca(le&take/up reel assem(ly, remove the old

assem(ly from the carrier panel $it should 2ust pop o0 and then install the

new one in the same spot. >efore doing so, take notice of how the ca(les

coming out of the ca(le&take/up reel assem(ly are routed. 6hen installing

the new assem(ly, make sure to route the ca(le that comes out of the top of

the assem(ly underneath the diagonal ca(le (etween the top front and(ottom rear pulleys. Gnce this is done, reinstall the window regulator motor

on the front side of the carrier panel. If you are not replacing the ca(le&take/

up reel assem(ly, go directly to step 19.

19. >efore installing the ca(les into the new/design clip (ody, make sure

that you have the correct clip for whatever door and window track you are

working on. The four regulator clips $(oth new and old are all di0erent and

will only work on their corresponding window track. The new clips are

la(eled with a code that indicates the door and window track that the clip

should (e installed on. '+' and '-' indicate that the clips are for the left and

right doors, respectively. '3' and '>' indicate that the clips are for the front$towards the front of the car when the carrier panel is installed on the door

and rear window tracks, respectively. Eor e7ample, a clip with the code '-/>'

should (e installed on the right door on the rear window track. imilarly, a

clip with the code '+/3' should (e installed on the left door on the front

window track. 3lso, (efore installing the ca(les on the new clip, make sure

to loosen the TB= Tor7 screw on the clip so that the window will slide into it

easily later on. Do not remove the (olt completely / only loosen it.

1). Install the ca(les into the new/design clip (ody (y following step 1 in

reverse. -emem(er to install the appropriate ca(le into the deeper groove

@rst. The ca(les should appear as they do in the picture (elow after (einginstalled.


44/57

;=. Gn the side of the clip, there is a small ta( which separates the two

ca(les and keeps them from ru((ing against each other. ake sure that one

of the ca(les runs on one side of the ta( and the other ca(le runs on the

other side of the ta(.


45/57

;1. Low it's time to install the new/design clip onto the window track / the

schematics (elow indicate how to do this. The process is (asically the e7act

opposite of the removal of the old/design clips from the window track.

imply insert the edge of the window track into the plastic +/groove insert in

the new clip $3 and then rotate the clip (ody into place on the track $>.


46/57

;;. The picture (elow shows a new/design window regulator clip installed

onto the window track.


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;B. If you did not remove and replace (oth regulator clips at the same time

$for whatever reason, remove and replace the regulator clip on the other

window track (y following steps 1; through ;;.

;:. Gnce (oth regulator clips have (een replaced, it's time to reinstall the

regulator ca(le on the pulleys. ake sure that the ca(le is installed correctly

on three of the four pulleys and then use a screwdriver to pop the ca(leonto the fourth and @nal pulley. ake sure that the ca(le guide $indicated (y

the yellow arrow in the picture (elow / there is one for each pulley is in

position. This procedure should (e relatively easy if the steel spring (racket

is in place on the ca(le&take/up reel assem(ly. If it is not, you'll need to

compress the springs on the assem(ly (y hand to provide enough slack for

the ca(le to (e installed on the @nal pulley. It helps to have a second person

compress the springs while you install the ca(le on the pulley. Lewer pulleys

have a cam pulley molded on top of each ca(le pulley which can (e used to

assist in reinstalling the ca(les if need (e $orry. I don't have a picture. To

use the cams, install the ca(le on one or more of the cams instead ofdirectly on the main pulleys / use as many cams as necessary to provide

enough slack to get the ca(le on all four cams&pulleys. Gnce the ca(le is in

place on the four cams&pulleys, pull down or push up on the two regulator

clips simultaneously. This will force the clips to move and will cause the

ca(les to rotate on the cams&pulleys. 3fter moving the clips a short distance,

the cams will pop the ca(le onto the main pulley / move the clips until the

ca(le is correctly installed on all four main pulleys.


48/57

;*. Gnce the ca(le has (een reinstalled on pulleys, dou(le check to make

sure that the clip replacement process has (een done correctly. Eirst, make

sure that the new regulator clips line up with the access holes in the carrier

panel $red arrows in picture (elow. If they do not, you'll need to reinstall the

clips in the correct locations. Le7t, make sure that the ca(le coming out of

the top of the ca(le&take/up reel assem(ly passes underneath the otherdiagonal ca(le, as indicated (y the (lue arrow in the picture (elow. Einally,

make sure that the ca(les sit on opposite sides of the small ta( on the edge

of the clip (odies, as descri(ed in step ;=. If the a(ove three conditions are

met, then the new regulator clips should (e installed correctly.


49/57

;. -emove the steel spring (racket from the ca(le&take/up reel assem(ly.

The window regulator system should now (e fully operational.

;. -einstall the carrier panel (ack onto the door / proceed directly to art I"

$(elow art III for these instructions.

+et me know if you have any Cuestions.A a",ay. )o t*! p#o$e)'#e at yo'# o,( #!3- I am (ot #epo(!b"e

&o# a(y m!ta3e !( t*e p#o$e)'#e o# t*oe t*at yo' ma3e ,*!"e

pe#&o#m!(+ !t-

odied by g)t* at 2:- & 30+-0-

Rep"y W!t* :'ote

:. V+Rt;

Mo)e#ato#

#oin Date

ar 9th, ;==;

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50/57

osts

1,1;)

3-T III / -4+3?IL% TH4 DGG- +G?! GD+4

=)/=9/;==B =)M*1 8B

PART III 4 REPLACING THE DOOR LOCK MODULE

The following section will (e very (rief. I have not actually done the

procedure yet and can only o0er some tips (ased on what I saw when I had

the window regulator carrier panel o0 to replace the regulator clips. I plan

on e7panding this section if&when I replace my own door lock module$s. y

driver's door module has (een acting up a lot recently, so this may occur

sooner than later. The "6 part8 for the driver's side door lock module in mycar is B>1/9B/=1*/# $this may or may not (e the same part8 as in your

vehicle / a Cuick search of door lock modules at I45 revealed Cuite a few

di0erent part8s. I'm not sure a(out the part8s for the door lock modules on

the other three doors.

If you own a !I" >entley manual $(ook, there is a half/decent procedure

for replacing the door lock module in ?hapter * / Eront Doors.

1. The picture (elow shows the location of the door lock module on the rear

edge of the window regulator carrier panel. The door lock module is

indicated (y the red arrow. It is attached to the carrier panel (y a plastic

(racket $yellow arrow. The door lock module is riveted to the (racket $green

arrow and the (racket is riveted to the carrier panel $(lue arrows. It

appears that the door lock module is replaced (y pushing out the plastic

rivets $from the rear side of the carrier panel / the side shown in the picture

(elow that connect the plastic (racket to the carrier panel with a small

punch and then using these rivets to secure the new door lock

module&(racket to the panel.

http://forums.vwvortex.com/showthread.php?1015107-DIY-Replacing-the-front-door-window-regulator-clips-and-or-door-lock-module&p=9506821&viewfull=1#post9506821http://forums.vwvortex.com/showthread.php?1015107-DIY-Replacing-the-front-door-window-regulator-clips-and-or-door-lock-module&p=9506821&viewfull=1#post9506821


51/57

;. The picture (elow shows the location of the microswitch $recognies if the

door is open or closed that commonly fails and makes the locking&unlocking

of the door and the operation of the alarm pro(lematic. I'm not positive, (ut

I (elieve that there may (e an additional microswitch inside the module

itself $recognies if the door is locked or unlocked. It appears that the

microswitch$es can not (e replaced separately and that the entire door lockmodule must (e replaced if one or (oth of the microswitches fails $very (ad

design IG / typical "6.


52/57

B. 3fter replacing the door lock module $or if you decide not to, reinstall the

carrier panel (ack onto the door / proceed directly to art I" $(elow for

these instructions.

EDIT5 S!($e t*! ,a o#!+!(a""y pote). ma#a!(,ate# 0Ma#32 *a

'$$e&'"y #ep"a$e) t*e )oo# "o$3 mo)'"e !( *! %e*!$"e '!(+ t*!DIY- He *a pote) ome mo#e pe$!


53/57

#oin Date

ar 9th, ;==;

osts

1,1;)

3-T I" / -4ILT3++IL% TH4 6ILDG6 -4%+3TG- ?3--I4- 3L4+

=)/=9/;==B =)M*; 8:

PART IV 4 REINSTALLING THE WINDOW REGULATOR CARRIER PANEL

1. ut the door lock module wire (unch and harness connector through thehole in the carrier panel shown in art I, step B:.

;. -eattach the door lock module harness connector.

B. -eattach the wire loom retaining clip $shown in art I, step ;* on the rear

of the carrier panel.

:. If you removed the carrier panel with the door lock module still attached

to the door, slide the inner door handle ca(le and the door lock pin through

their respective holes in the carrier panel.

*. -einstall the carrier panel onto the door (y following art I, step B; in

reverse. There are two aluminum registration pins on the front and rear

edges of the carrier panel that need to @t into their corresponding holes in

the door. The holes for the ten $1= 1=mm (olts that secure the panel to the

door will only line up if the registration pins are in place. Gne of the pins is

indicated (y the yellow arrow in the picture (elow.

http://forums.vwvortex.com/showthread.php?1015107-DIY-Replacing-the-front-door-window-regulator-clips-and-or-door-lock-module&p=9506835&viewfull=1#post9506835http://forums.vwvortex.com/showthread.php?1015107-DIY-Replacing-the-front-door-window-regulator-clips-and-or-door-lock-module&p=9506835&viewfull=1#post9506835


54/57

. ?heck if the ru((er weather seal around the edge of the carrier panel is

seated correctly. The seal is indicated (y the yellow arrow in the picture

(elow.


55/57

. If the seal is seated correctly, you should (e a(le to see it (etween the

edge of the carrier panel and the door around the entire circumference of

the panel, as indicated (y the red arrow in the picture (elow. Ei7 any spots

where the seal does not appear to (e seated correctly.


56/57

9. -einstall the ten $1= 1=mm (olts that secure the carrier panel to the

door.

). -eattach the ru((er grommet for the door lock module wire loom shown

in art I, step ;*.

1=. -eattach the si7 $ wire loom retaining clips shown in art I, step B=.

11. -econnect the window motor harness connector (y following art I,steps 1B and 1: in reverse.

1;. If you did not loosen the TB= Tor7 screws on the new regulator clips

(efore installing them, raise&lower the clips using the window controls on the

'other' door until the screws are visi(le through the access hole in the carrier

panel and then loosen $do LGT remove the screws. >e careful to make sure

that the window glass slides into the the clip opening if the clip and glass

are close to each other when doing this step.

1B. -aise the window glass until the (ottom of the glass seats in the clip

opening. 3fter you're con@dent visually that the glass is seated inside the

clips, raise the clips slightly more. If the window moves upward slightly, thenthe window is seated in the clips properly.

1:. lide the window all the way toward the rear of the car and then tighten

the TB= Tor7 clip screws to 1= L/m $9) in/l(. I didn't use a torCue wrench

and 2ust tightened the screws hand tight.

1*. -emove the duct tape from the window and the rag from the top of the

door.

1. ?lean the tape residue o0 of the window. ?itrus degreasers work great

for this 2o(.

1. -eattach the access hole grommet covers shown in art I, step .

19. -einstall the two $; door lock module (olts on the rear edge of the door$shown in art I, step ;:. 3pply some (lue&medium strength +ocTite to the


57/57

threads if you have any.

1). -eattach the outer door handle ca(le (y following art I, steps ;1

through ;B in reverse.

;=. -einstall the door handle (lank shown in art I, step ;=. You may need to

pull the outer handle out slightly to allow the (lank to slide in completely.

;1. Tighten the handle (lank retaining screw shown in art I, step 1).;;. -eplace the small plastic cover on the rear edge of the door $shown in

art I, step 1.

;B. If you removed the carrier panel with the door lock module still attached

to the door, reattach the ru((er grommets for the inner door handle ca(le

and the door lock pin shown in art I, step 1.

;:. -eattach the harness connector for the woofer.

;*. -eattach the harness connectors for the tweeter and side/view mirror

and install the harnesses (ack into the harness carrier shown in art I, step

*.

;. -einstall the inner door trim panel using the directions in the followingDIY / -emoving front door parts.

+et me know if you have any Cuestions.

A a",ay. )o t*! p#o$e)'#e at yo'# o,( #!3- I am (ot #epo(!b"e

&o# a(y m!ta3e !( t*e p#o$e)'#e o# t*oe t*at yo' ma3e ,*!"e

pe#&o#m!(+ !t-
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