V641504 2016012

Technical Bulletin
Model(s)
Year
Eng. Code
Trans. Code
VIN Range From
VIN Range To
Beetle
Convertible
2003-2008
All
All
All
All
Beetle
Convertible
2009
All
All
1Y_9M000001
1Y_9M411526
Condition
64 15 04 December 3, 2015 2016012 Supersedes T. B. V641202 dated April 23, 2012 due to applicable models
are no longer covered under warranty and grease G 00045003 being discontinued.
Window, Rear Side, Inoperative
Rear side window inoperative or will not roll up.
Technical Background
1. Rear window symptoms may include:
 Noise heard during open and close operation
 Will not close
 Inoperative
Window regulator cable retainer is broken. The material of the
retaining clip (POM) is too hard.
New material change was implemented to improve the part
flexibility.
Page 1 of 11
© 2015 Volkswagen Group of America, Inc.
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intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
2. Insufficient use of grease in window regulator guide rails (A, B, and C below) on carrier plate.
Production Solution
 Grease is used in the cursors and the rail guides of the window regulator beginning with VIN
3VWRF31Y28M420764 (CW 15/08).
 Material modification to POLYAMIDE 6.6. New cable retainer is identified by "polyamide 6.6" beginning with
VIN 1Y_9M411527 (CW 20/09).
Page 2 of 11
© 2015 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
Service
 If regulator replacement is required, perform REGULATOR REPLACEMENT
 If regulator replacement is not required, perform LUBRICATE CURSERS AND GUIDES – ON VEHICLE
REGULATOR REPLACEMENT
Tip:
When window module is disassembled, verify that the cable and cursor parts are in order, and apply grease as
mention in lubrication of carrier plate.
 Remove rear window carrier plate, see Repair manual
group 64 Glass, Window regulators, in Elsa.
 Place window carrier plate on a clean and protected
surface.
Note:
DO NOT remove the glass from the carrier plate.
DO NOT loosen adjustment bolts located above and below
lower pulley.
Tip:
In an effort to save labor time, cut the original window cables as
necessary. The cable housing will be replaced during this
procedure.
 Manually extend or retract window from carrier plate to gain working
access to slider.
 Remove the slider retainer nut and discard.
 Lift cable retainer off of stud and discard.
Page 3 of 11
© 2015 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
 Remove washer with tensioning spring and discard.
 Remove slider base and discard.
 Free window cables by cutting the tie strap -arrow- at upper carrier plate
support.
Page 4 of 11
© 2015 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
 Carefully invert the window regulator assembly.
 Remove the window regulator fasteners and separate the window
regulator from carrier plate support, see Repair manual group 64 Glass,
Window regulators, in Elsa.
 Separate window motor from the original cable housing.
Tip:
A small flat screw driver may be used to separate the window motor from original cable housing.
Note:
Care must be taken when removing tie straps from new cable housing, prior to attaching the housing to the window
motor. The cables are not spring loaded but may become misaligned if handled improperly. Should the new cable
housing lose its indexing see, Re-indexing Cable Assembly at the end of this procedure.
 Remove the tie straps from new cable guide housing and
place new cable housing on window motor.
 Mount window motor to carrier plate using reference tabs
and new screws from kit.
 Tighten window motor in cross sequence to 3.5 Nm (31 in.
lbs.).
 Pass the cables through carrier plate support brace (as
required).
Page 5 of 11
© 2015 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
 Lubricate inside of Curser (slider base) with polyurea based
grease (obtained locally) and then place the Curser (slider
base) onto carrier plate guide.
 Install new tensioning spring with grease.
 Install 0.5mm washer on top of spring.
 Fit upper and lower cable ends into new cable retainer.
 Ensure cables are fully seated.
Tip:
Ensure upper and/or lower cable is routed through carrier plate
support brace as required.
Page 6 of 11
© 2015 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
 Place cable retainer and new 1mm washer onto slider and
tighten nut to 2.5 Nm (22 in. lbs.).
Tip:
The window and frame assembly may be manually extended
or retracted to gain proper positioning of cable assemblies.
 Route upper cable around upper pulley and seat upper
cable guide into slot -arrow-.
Page 7 of 11
© 2015 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
 Carefully position the opposite end of the upper cable onto
motor.
Note:
The window must be retracted to its lowest position to
compress the spring -arrow-.
This action will release tension from cables to ease installation
onto pulleys.
 Retract window and frame to gain maximum slack in cable
assemblies.
 Position window cable on to special tool VWM 100 (Window
Cable Installation Tool) and fit tool onto lower pulley.
 Twist special tool VWM 100 until tool overcomes the upper
cable spring tension and seats cable in lower pulley.
Tip:
Care must be taken to ensure proper position of upper cable
during this operation.
Use the notches in the lower pulley to assist cable installation
on lower pulley.
 Secure upper cable with tie strap -arrow-.
Tip: The natural curve of the upper cable into the window
motor assembly must be preserved.
 Lubricate both carrier plate guides along the entire run of
window with polyurea based grease (obtained locally).
 Install and adjust rear window regulator.
Tip: Perform rear window relearn procedure - use key in
driver's door and run window full up and down.
See Repair Manual group 64 Glass, Window regulators, in
Elsa.
Page 8 of 11
© 2015 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
Re-indexing Cable Assembly
 Seat the lower window cable in the cable guide groove.
 Wrap upper window cable 3 times around the cable guide
and insert the guide with cables into the cover assembly.
 Ensure the upper window cable (heavy rubber sheathing)
rides on top of the lower window cable (bare cable), and
the cable spring is located at the gear housing, before
positioning the housing onto window motor.
Tip:
Right side shown - left side is opposite where rubber sheathed
cable is on the bottom of the bare cable.
 Before reinstalling, lubricate window regulator guide rails A,
B and C (arrows) and cursers on both sides of carrier plate
with polyurea based grease (obtained locally).
LUBRICATE CURSERS AND GUIDES – ON VEHICLE
 Lubricate window regulator guide rails A, B and C (arrows)
on both sides of carrier plate with polyurea based grease
(obtained locally).
Tip: This procedure can be performed on vehicle. Do not
remove window regulator.
Page 9 of 11
© 2015 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
 Remove interior trim to gain access to the rear window
regulator assembly. See Repair Manual group 64 Glass,
Window regulators, in Elsa.
 Disconnected regulator harness for easier access to guide
rails.
 Apply polyurea based grease (obtained locally) to front and
back of guide rails (A, B and C above) and cursers using
wedge tool Part No: 3409.
Tip: Only a small portion of the forward rails “A” and “B” arrow- are accessible. The method to distribute the grease will
be to cycle the window up and down after grease application.
 Connect regulator harness and cycle window up and down
to distribute the grease. Apply more grease and cycle
window if necessary.
 Place window at mid position and disconnect regulator
harness. Apply grease to center “B” rail curser -arrow-.
 Connect regulator harness and cycle window up and
down to distribute the grease. Apply more grease and
cycle window if necessary.
Page 10 of 11
© 2015 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
Warranty
Information Only.
Required Parts and Tools
Part Description
Part No:
Quantity
Polyurea based grease
obtained locally
-
Window Cable Housing Kit, Left
1Y0898291
1
Window Cable Housing Kit, Right
1Y0898292
1
Tool Description
Tool No:
Quantity
Wedge
3409*
1
Window Cable Installation Tool
VWM 100*
1
Additional Information
All part and service references provided in this Technical Bulletin are subject to change and/or removal.
Always check with your Parts Dept. and Repair Manuals for the latest information.
Page 11 of 11
© 2015 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.