Windshield Wiper Fix: Passat 35i (Permanent Solution)

Hello everyone,

I have a Passat 35i, model year 1992, with a 1.9 TD engine (specifically, the AAZ engine), and I'm having a frustrating problem.

Whenever I replace the fuse for the front windshield wiper, it blows again after a short time (sometimes after a few hours). Afterward, there's a very strong, unpleasant smell coming from the fuse box.

Is this a 'typical' problem, and can you give me a likely diagnosis, or do I need to provide more details? There can't be that many possibilities. Maybe it's a relay, or a broken wire, or something is shorting out against the body of the car. Could it also be the wiper motor (a short circuit)?

What do you think?

Sure, here's the translation:

'Thank you in advance.'
Rey (who hopes not to make any mistakes as a newcomer here, please be patient).

Okay, there are a few things that could be the cause. Start by checking the windshield wiper motor, disconnect the connector in the washer fluid reservoir, and then replace the fuse. If the problem persists, there's likely an issue with the motor itself. If the fuse blows again, it becomes more complicated, as you'll need to check the entire wiring harness. Perhaps the connector on the wiper motor is damp or corroded? Although, with the current temperatures, that's less likely.

'When I replace the fuse, the windshield wipers work perfectly for a short time, as they should. However, it doesn't last long. Within about 10 seconds, the fuse blows again. Then, there's a terrible smell of burning wires inside the car, which is not pleasant.'

Is the windshield wiper moving at a normal speed, or is it a bit too slow? It's possible that the wiper linkage is stuck, which would cause the wiper motor to draw more power. However, this shouldn't be a common problem with Passat cars.

Hello Rey,

Nothing helps in this situation. You need to address your problem, as suggested by matthiasTDI96.
Okay, first, disconnect the power connector from the windshield wiper motor and replace the fuse. If the fuse holds and there's no smell of burnt wires, you've located the problem.

However, if the fuse continues to blow, it becomes more difficult to find the cause. Because your wiring is likely getting very hot (you can smell the burning insulation). This doesn't indicate a direct short circuit, but rather an overload. This could be caused by a faulty windshield wiper motor or damaged cable insulation.

Make sure to fix the problem before any cables or circuit breakers catch fire. In the worst-case scenario, your car could completely catch fire.

So, good luck!!!

Best regards, Georg.

Hi!
Just a quick tip regarding Matthias' good approach:
"If the windshield wiper motor is disconnected, I would either install a SIGNIFICANTLY smaller fuse (e.g., 1A) or use an ammeter to check the current draw. This would help avoid further stressing the cable insulation, as the 1A fuse would likely blow immediately..."
If I suspect that the cables in the car are already starting to melt, I would probably take a closer look and inspect the wiring as thoroughly as possible. I wouldn't want the hardened insulation to wear away over the next six months...

Best regards,
Dirk.

Hello everyone,

Thank you very much for your quick and competent assistance.

This afternoon, I disconnected the motor and installed a 10A fuse, and sure enough, it stayed intact. The tip about using a smaller fuse is worth its weight in gold, or even platinum. Unfortunately, I haven't been able to find any burnt cables yet, maybe it was just the fuse that was causing that burnt smell. Admittedly, it smelled like a lot of burnt stuff, but who knows.

The engine turns freely, and when it's running, it operates correctly in all gears. However, the fuse doesn't blow only when I turn on the windshield wipers; it blows randomly. You can hear a clicking sound from the fuse box, the wiper briefly twitches, and then it starts to smell like burning.

I guess I'll have to test the motor, or better yet, just replace it. Hopefully, that's actually the problem.

Thanks again to everyone, great forum (I'll be staying here with my 'Pöl' Passat and 'Pöl-Pölo' - and of course, enjoying the outdoors).

Greetings.
Rey.

Hello,

Okay, as I said, the fuse kept blowing even with the motor disconnected. So, yesterday I installed a new motor, along with the complete linkage, in case that was too heavy.

What can I say? After I fixed everything, it looked good, but then the fuse blew again after just half an hour. So it wasn't the motor after all, and I wasted my money.

I couldn't see any damage to the cables, no signs of wear or abrasion, and the relay seems to be okay.

I suppose I'll have to run four new cables from the fuse box as a test, and hopefully, that will eliminate the wiring harness as the problem. What else could it be?

greetings
Rey (the desperate one)

Hello!

Old topic... but I'm still interested in the outcome. I'm currently experiencing the same problem. The fuse blew twice in a row, and the third one is still holding, so I can't take any measurements right now .

In the Passat 35i, it frequently happens that the wiring harness near the steering column shorts out.

Remove the steering column cover and check everything. There are some funny things that can happen, like the low beam always being on, all the turn signals lighting up, and other quirks... it even appeared on a car show once.

Hi!
Das ist auch als Erstmaßnahme geschehen. Also die ersten 10cm ab dem Zündschloß sehen einwandfrei aus. Und danach kommt ja eigentlich schon bald der gut isolierte Kabelbaum. hm. Mist.


Sure, here's the translation:

"Thx!!"