Audi 80-90 B3 (1986-1991) Service manual

Audi 80-90 B3 (1986-1991) Service manual
+
~ Glass, Window Regulators
Index
Power window regulators
= front door assembly 64.15
= Operating switches,
checking continuity 64.25
# Operating switches,
removing/installing 64.24
= rear door assembly 64.16
s safety switch,
checking continuity 64.25
в Safety switch,
removing/installing 64.24
= thermofuse, location 64.26
m troubleshooting 64.17
"Rear window
= installing 64.9
= removing 64.8
Side windows
E installing 64.12
E removing 64.11 A
Window lifter pivot
= repairing 64.38
Window regulator assembly
“« inspecting 64.27
Window regulator drive cable
s replacing 64.40
Window regulator motor
a disassembly 64.28
= inspecting/Cleaning 64.31
= reassembly 64.32 ..
= replacing 64.34
и”
Ed
Window replacing
в general information 64.2
Windshield
# installing 64.6
| = removing 64.4
E |
Coupe
Center spacer
s installing 64.49
Power window regulators
m Circuit breaker, location 64.59
а Operating switches,
checking continuity 64.59
se operating switches,
.removing/installing 64.58
= regulator,
checking/replacing 64.57
e troubleshooting 64.51
Side windows
= removing/installing 64.50
Window regulator motor
= replacing 64.60
Window replacing
‚ов general information 64.42
Windshield .
u- dnstaling 6447-—.....
» femoving 64.45
^^
64. 1
Glass, Window Regulators
Window replacing, general
information
To replace windshield, rear window or side
windows, the following tools and materials are
required. ‚
Tool kit VW 1474 |
1— Reel
2 — Relay roller with holder
3 — Awl
4 — Guide rail
§ — Protective sheeting
Use protective sheeting VW 1474/7 to protect
instrument panel.
£
Tool kit VW 1351
e for removing broken windshields, rear
windows and broken or unbroken side
windows
CAUTION
Te prevent paint damage, mask
perimeter of windshield, rear and side
windows with cloth duct tape.
o caulking gun
® double suction pad (only for rear window, -
windshield) -
——— protective goggles |
e utility knife ———.
¢ e protective gloves (leather) To
e cloth or duct tape -
a
A-2
) “ Window replacing, 6 4
general information 22 -
Glass, Window Regulators
N
Parts required
CAUTION
Part numbers are listed for reference -
oniy. Always consult with the Parts
Department for latest information.
o.
Description Part number | Quantity
center spacers 893 845 631 1
for windshield
adjusting wedges | 893 B45 631A 2
for rear window | 893 B45 515A
cutting wire 50m | 443 845 955 +1
{150 ft) roll
adhesive kit D 004 300 03 1
(vehicles with
airbag)
adhesive kit D 004 300 04 1
(vehicles without
airbag)
Mixing rod (For | D 009 700 1
use with adhesive
kit D 004 300 04)
Hardening of adhesive sealing compound
Vehicles without airbag
a vehicle must stand at least one hour, at
room temperature of 20°C (68°F) and
relative humidity of 65-70% before allowing ’
vehicle 10 be driven
Vehicles with airbag
® vehitie must stand at least three hours, at
room temperature of 20°C (68°F) and
relative humidity of 85-70% before allowing
vehicle to be driven `
® keeping the sealed/bonded area wet forms
‘a skin that promotes hardening process
— TEA a
- A-3
Ebo! . -
%
сн
Window replacing,
aeneral information
64.3
В Glass, Window Regulators
Surplus bonding/sealing compound,
removing
CAUTION e
When using any cleaning agent, follow
all cautions and warnings listed on the
containers.
8 first use dry cloth fo clean off painted areas
8 excess adhesive sealing compound can be
removed using a cleaning solvent such as.
supplied in repair kit
® do not use cleaners which contain
alcohol |
8 to clean plastic tim, let adhesive sealing
compound harden two to three hours, then
scrape off excess with plastic wedge
¥
” Sealing leaks
- CAUTION
While adhesive sealant is hardening,
avoid putting pressure on glass from
inside car when cleaning around glass.
| . 8 water test window area before reinstalling
< moldings, trim or lip or rubber molding
X 8 dry area around leaks with compressed air
and clean
® apply adhesive sealant from outside to leak .
area between glass and flange then У
smooth over |
‚ ® retest area for water leaks
Note - %
| 7 The small adhesive sealant cartridge ‘
* В - D 009 100 03 is recommended for resealing.
i 2
A-4
— i . : *
DIN ——— _ _—_ Window replacing, 64 . -
| ” general information "CP » Sa
-Glass, Window Regulators
= 7
S
| =
64-152
Body
change
Adhesive sealant Cutting wire
- [64-144]
Pa
Windshield, removing
a 8 EE B®
3
remove A-pillar trim (see Repair Group 70) -
remove beading from headliner
remove windshield wipers 7
remove plenum chamber cover (as shown)
disconnect wiring for front antenna
WARNING
Always wear protective goggles and
leather gloves when removing and
installing windows.
remove tnner rear-view mirror
® press downward (arrows) at angie
(spring clips in mirror mounting)
cut off 6.5m (21 ft) cutting wire
locate center of cutting wire
on the outside, starting at top center of
windshield, press cutting wire under rubber
molding so wire runs completely around
perimeter of windshield ending at bottom
center
CAUTION
Do not bend or twist wire, otherwise wire
will break when under tension.
AS
Windshield, removing 64.4
CAUTION
Depending on extent of paint damage
in removing windshield, touch-up or
repaint as required.
Glass, Window Regulators
Mm from inside push aw! through adhesive
sealant at lower right corner (as shown)
until awl eye is visible from outside
m turn awl slightly and thread in one end of
wire -
® bend over wire and pull through to inside of
vehicle
m do same at lower left corner with other end
of wire
Mm remove guide rail
—
“+
CAUTION
Ends of wire must be in adhesive
sealant as close together as possible,
but must not overlap, otherwise glass will
break or wire will bend or twist.
m attach relay roller with holder
into left and right lower corner of windshield
e holder must support on dashboard (arrow)
mM attach reel (as shown) to center of...
windshield ВЫ
E guide wire up from base of windshield and
around relay rollers then thread ends into
reel A
wm slightly tension cutting wire with reel and
ratchet A
® check that wire is placed correctly around
comers and molding before cutting
mM start cutting and continue cutting operation
until relay rollers are clear
m remove relay rollers
a cut out windshield completely
br
Note
If cutting wire breaks several times (wire gets
caught on the windshield flange) and can no
longer be fitted on the reel (wire too short),
cut remaining area with tool VW 1351 (pulling
handle and mounting).
A-8
Windshield, removing 64 " 5
Glass, Window Regulators :
tL
Windshield, installing
If windshield is to be reused. cut away
enough old adhesive sealant with utility knife
around glass and body flange to give smooth
uniform surface.
if body repair has been done, body flange
must be cleaned and primed with primer from
adhesive kit.
> m attach molding around windshield
E install joiner 1 into recess 2
Em Clean edge of glass approximately 30mm
(1-11/64 in) wide with cleaning solvent and
wipe dry with lint-free cloth
Ceramic black-out band around windshield is
| not primer. Before applying adhesive sealant
> a prime this area with primer D 009 200.
777 E Y m cut applicator head .
LL 77720 € | E insert felt into applicator head
| E thoroughiy shake bottle of primer
+ (approximately 30 seconds) and fill
“applicator bottle 4
e ~ m attach application head onto bottle
> wm apply primer a = 20mm (7/8 in) wide
64-147 evenly all around edge of windshield in one
continuous operation. Ensure applicator
head is always completely saturated
e drying time approximately 10 minutes
WARNING
Adhesive used in bonded window
glass installations, original or
replacement, may give off toxic fumes
when heated. Read container labels.
Ensure adequate ventilation.
Note "
Do not retouch strip of primer until it has
dried completely.
А | | > m apply adhesive sealant around windshield,
making sure that the adhesive sealant -
touches the edge of the windshield
т == A b = 8mm (5/16 in)
o > ppm, - с = 8mm (5/16 in)
d IX d = 12mm (15/32 in)
— € В Note |
Reduce the height of adhesive by the
thickness of the adhesive remaining on the
windshield or the windshield body flange. a
+
e
Windshield, Installing 6 4 ® 6
CAUTION
Vehicles with airbags must stand at
least three hours. at room temperature
ot 20°C (68°F) and a relative humidity of
65-70% before allowing vehicle to be
| driven.
Vehicles without airbags must stand for
À at least one Hour.
Glass, Window Regulators
m place windshield into position using two
double suction pad holders |
m align windshield at the sides .
E insert adjusting wedges 1 into corners o
windshield (as shown)
® wedges do not have to be removed
m align windshield gap e at top to
3-4 mm (1/8-5/32 in.)
a lightly press windshield into place
8 press windshield at top until windshield
molding is flush with roof
® test for leaks
m clean off surplus adhesive sealant from
body and glass
® reinstall trim piece
Windshield height spacers
Audi 90 only
Note
In order to maintain proper spacing between
windshield glass and body flange, three
spacers. must be installed near the lower
windshield edge when replacing the
windshield. ,
All dimensions are + 2.0 mm (+ 5/64 in.).
г
Side spacers, installing °
«= remove paper backing from spacers (self
adhesive)
@ apply spacer next to adhesive strip (
shown) _ | |
a = 25 mm (1.0 in.)
Center spacer, installing
E remove paper backing from spacer (self
adhesive) . » |
‘wm apply spacer in center of glass (as shown)
1 — trim strip
2.— windshield
3 — spacer
4 — body flange
a = 25 mm (1.0 in.)
A-8
‘Windshield, instaliing 6 4
Windshield height spacers, installing | of
WARNING
Wear protective goggles and leather
gloves when removing and installing
glass. ;
v Molding with rubber tip
Glass À \_
’ Tr 774)
A o —|
Adhesive sealant \ Cutting wire >
Wy
Glass, Window Regulators
Rear window, removing
Note
When removing a broken rear window, cut
adhesive on glass and body flange while
removing pieces of broken glass. Do not
remove all of adhesive.
8 remove D-pillar trim
® unplug, unscrew connectors for heatable
glass and rear window antenna -
a tape connections out of way (in center of
glass) ‚
am remove high mounted brake light assembly
am cut off 6.5m (21 ft) cutting wire
E find center of cutting wire
m starting at top center of glass, press cutting
wire under rubber molding so wire runs
completely around perimeter of window
ending” at bottom center
Note
Do not bend or twist wire, otherwise wire will
break when under tension.
a insert ends of cutting wire separately into
lower corners of glass and guide inwards
into comers (as shown)
e do NOT twist
sm push awl through adhesive sealant until awi
eye is visible from outside
m turn aw! slightly and thread in one end of
wire |
a bend over wire and pull through to inside of
vehicle
a do same with other end of wire
® remove guide rail
a attach relay roller with holder into left and
right lower corner of glass (as shown)
e holder must support on rear panel
m. attach reel (as shown) to center of glass
m guide wire up from base of glass and
around relay rollers |
A-9
Rear window, removing 6 4 = 8
Glass, Window Regulators
twist.
CAUTION
Ends of wire must be in adhesive
sealant as close as possible together,
but must not overfap. otherwise glass
will break or wire will bend and/or
ЧЕ " = ” ЧЕ mE
в” : an
r Tena
+
=
CAUTION
Depending on extent of paint damage
in removing rear window, touch-up or
repaint as required.
7777 LL
LLL LLL =
>
thread ends into reel
- © slightly téhsion cutting wire with reel and
ratchet
# check that wire is correctly around comers
and molding before cutting
E start cutting and continue cutting operation
until relay .rollers are clean
# remove relay rollers
E continué to cut out rear glass
Note
If the cutting wire breaks several times (wire
gets caught on the window flange) and can
no longer be fitted on the reel (wire too short)
this area can be cut through with tool 1351
(pullihg handle and mounting).
Rear window, installing
If rear window is being reused, cut away
enough old adhesive sealant with utility knife
around glass and body flange to give smooth
uniform surface. —
If body repair has been done, body flange
must be cleaned and primed with primer from
adhesive kit.
® attach molding around glass
w install joiner 1 into recess 2
Lp
w clean edge of glass approximately
30mm (1-11/64 in) wide with cleaning |
solvent and wipe dry with lint-free dry cloth
Note a | | 7
Ceramic black-out band around window is
not primer. Before applying adhesive sealant
prime this area with primer D 009 200.
A-10
Rear window, removing/installing 64 в 9
Glass, Window Regulators
— b
taa ии
TT te НР РЗ,
jr —[]— An
d a
e
& cut applicator head
B insert felt into applicator head
в thoroughly shake bottle of primer
(approximately 30 seconds) and fill
applicator bottle
Em attach applicator head onto bottle
m apply primer a = 20mm (7/8 in) wide
evenly all around edge of glass in one
continuous operation. Ensure applicator
head is always completely saturated
e drying time approximately 10 minutes
Note
Do not retouch strip of primer until it has
dried completely.
E bend open connections for window aerial,
heated window glass
® bend 90° to glass
8 apply adhesive sealant around rear window
making sure that the adhesive sealant
touches the edge of the glass
b = 8mm (5/16 in)
Pc = 8mm (5/16 in)
° @ = 12mm (15/32 in)
sm remove protective backing from wedges
Part No. 893 845 515A
m bond wedges 2, on body flange A, between
adhesive 1 and edge of defroster/antenna
element 3 `
Note E
Reduce the height of adhesive by th |
thickness of the adhesive remaining on the
rear window or rear window flange.
CAUTION
The distance between the adhesive and
the bus (heated rear window and window
antenna) should be at least 10mm
(25/64 in).
When window is Installed, the spacing
over the entire length must be at least
3mm (1/8 in).
If the adhesive makes contact with the” /
bus, there will be no radio reception with
_ the window antenna.
A-11
- Rear window, installing 64 al 0
Glass, Window Regulators
A-12
CAUTION
Vehicle must stand at least three
hours, at room temperature of 20°C
(68°F) and a relative humidity of
65-70% before allowing vehicle to be
driven; |
® place rear window into position using two
double suction pad holders
® align rear window at sides
® insert adjusting wedges 1
Part No. 893 845 631A into corners
of rear glass (as shown)
e¢ wedges do not have to be removed
® align window glass gap e at top to 3-4mm
(1/8-5/32 in)
® lightly press in rear window
E test for leaks
E clean off surplus adhesive sealant from
glass or body
E reinstall trim
wh
+
Side windows, removing
Removing
é
Ta
\
"a
® remove D-pillar trim (see Repair Group-70)
® remove rear bench and backrest (see
Repair Group 72) à
в remove C-pillar trim (see Repair Group 70)
E pull out rubber. gap cover 1 (as shown)
m cut panel 2 from window with utility knife
e only on unbroken windows.
w
roa GB -
® bend retaining plates away from frame
(arrows)
2
® mask window opening at bottom (side
section) and D-pillar with duct tape
+
-
Rear window, installing
Side windows, removing
w
64.11
as Glass, Window Regulators |
Removing broken window и
B remove pieces of glass up to the adhesive
sealant,
E remove remains of glass and adhesive
sealant from body flange using cutting tool
VW 1351 and knife
+
Note
&
If gap between glass and flange is less than
5mm (1/4 in) use only a utility knife to
remove pieces of broken glass (as shown) -
Unbroken window, removing
_ # working from interior of vehicle, use pliers
to push cutting ‘wire (approximate length
350-400mm, 14-16 in) through adhesive
sealant between window and body flange
Mm Secure cutting wire with the wire ends at |
X and Y of the cutting tools ‚ >?
e part X goes in the interior of the vehicle |
e part Y goes on the outside of the vehicle
s thread wire in direction of arrow, A clamp
on, or B screw on
« M insert cutting tool X into adhesive sealant
. and secure
® using handle Y, pull wire evenly in direction
of arrow (as shown) until retaining lug is
reached
s pull wire with cutting tool X inwards, insert
into adhesive sealant approximately
100-150mm (4-6 in) further on and secure
« continue pulling until next retaining lug is
reached and then repeat procedure until
completely cut out
om
A
4
5
`
1
1
`
+
r
À
м ma *
А.13 ` | Side windows, removing/instailing 64 al 2
Glass, Window Regulators
CAUTION
Depending on extent of paint damage
in removing side window, touch-up or
repaint as requi
Tu
- Side windows, installing
If an unbroken window is to be reused, use a
utility knife to cut any remaining adhesive
sealant on the glass and metal flange back
until smooth. ‚
e do not remove completely
The remaining sealant acts as a base for
application of new adhesive sealant. Keep
surfaces free of dirt and grease.
Note
If body repair has been done, body flange
must be ciedned and primed with primer from
adhesive kit. us
Note
The ceramic black-out band around glass is
not primer. Before applying adhesive sealant,
prime this area with primer D 009 200.
E apply primer a = 20mm (7/8 in) wide
evenly all around edge of glass in one
continuous operation. Ensure applicator
head is always completely saturated.
® drying time approximately 10 minutes is
/ | CAUTION |
Do not retouch strip of primer until it has -
completely dried.
‚+
-
E apply adhesive sealant all around window,
making sure that the adhesive sealant |
touches the edge of the window moilding. . '*
b= 8mm (5/16 in) ,
с = 8mm (5/16 in)
. Side windows, installing 64 «13
Glass,
Window Regulators
~ CAUTION
The rear door {contact area between
the door seal and the newly bonded
window) must remain closed during
the curing period. After three hours
vehicle may be driven.
a”
, ® reduce the height of adhesive by the
thickness of the adhesive remaining on the
glass or body fl
Note
ange
À mounting kit is available when reinstailing
glass.
8 remove backing off adhesive strips of
retaining plates
® retaining plat
parts
es only on replacement
-B insert window into place
® align window, ensure rubber gap cover fits
evenly around
® bend retaining plates so that adhesive
strips are supported
# clean outside of window around trim plate
1 in adhesive area with cleaning solution
from adhesive
kit
® apply primer on trim plate 1, C-pillar 3
m apply adhesiye
sealant to trim plate 1
° bead‘tmiékress 4.0mm (5/32 in) diameter
E secure window
cloth tape
® test for leaks
glass and trim plate with
# clean off surplus adhesive sealant from
glass and body
А.15
\
Side windows, Installing 64 . 1 4
CONTINUED IN THE
"BEGINNING OF NEXT ROW |
ъ ; А.16
_ Glass, Window Regulators
. 3 oy
o a5
- right front
o Fr р ot ©?
a
Operating switch Auxiliary relay board
tor window regulator adapter mounted on side
Terminal connector Control unit
for wi . for window regulator
Control pane!
with switches
remove from top
Wiring harness
see appropriate wiring
diagram for routing cla
гетомпоя нано раде 64.24 -
Operating switches for
window reguiators ”
removing/installing page 64.24
Mounting bolt
- Door glass .
‘left front
see appropriate wiring
diagram or relay locations -
> Door component carrier
de .
| Door contact switch
left tront +
Ground connection |
A-pillar, insi icle
on A-pillar, inside veh Mounting parts
for door glass
Terminal connections —
under instrument panel,
left side
Nut Terminal connector бо iat
left front window wi "ua
regulator motor checking/replacing, page 64.23
not directly connected to 8
operating gwitch
[ere]
5 - — B-2
———— 64.15
Glass, Window Regulators
Terminal connection
operating switch, rear right
removing, page 64.20
Operating switch
for window regulator, rear
removing, page 64.20
Terminal connector
operating switch rear, left
_ removing, page 64.20
Door glass
rear left
B-3
rare wien. 64.16
Glass, Window Regulators
Troubleshooting — power window
regulators
Note
Refer always to appropriate wiring diagram.
Test conditions
e battery OK
e rear window safety switch disengaged
e with ignition on, control unit “clicks” when
drivers window switch activated
Tools required
"e multimeter US 1119
e LED tester US 1115
e test adapter VW 1594
e sun VAT 40 or VAT 60 or equivalent with
current test lamp
No window operates
No power
E remove left lower dashboard cover
E pull control unit from auxiliary relay panel
m connect tester to terminals 14 and 2
e must read 12V
y RB connect tester to terminals 14 and 1
® turn on ignition
e tester must read 12V'
specified values NOT | specified values OK
OK
Y Y
m repair break in Go to
electrical wiring | |
or | page 64.18
m replace
. —| —thermofuse ——
4
End -
B-4
Power re: 64.17
Glass, Window Regulators
0
Checking front door contact switches
® connect tester to terminals 14 and 3
e specified value 0 ohms
Mm press right front door contact switch
* specified value « ohms
< E connect test device between terminals 14
and 6
e specified value 0 ohms
Mm press left front door contact switch
e specified value x ohms
specified values NOT | specified values OK
OK
y Y
_ Mm repair break in | reinstall control
electrical wiring unit
1 y
End Go to
page 64.20
B-5
Ë troubleshooting «18
\
O
wor
Glass, Window Regulators
front, or rear door window not
с
| Checking window regulator current draw
(installed)
Ne
| = zero tester to compensate for other
E connect volVamperage tester
Sun VAT 40, or VAT 60 or equivalent
e Sun VAT 60 shown
Em connect inductive pick-up to battery
ground strap
® switch ignition ON
E press operating switches for window
regulators one after the other (open or
close)
E measure current draw during window
switch operation
e must be 6-12A (during window travel)
Note
The tester will always indicate a certain
current reading when the ignition is
switched on; this reading will vary according
to operating conditions and the type of
model and equipment, to correct:
electrical consumers - -
m after glass is at top or bottom and switch
depressed, current must be between
15-20A (stall current)
Sy
1
нежен!
‘ Y
pyerarare"
22 CT specified stall current
values NOT | OK
OK window does
Tno current | not move ——
Ÿ draw ‘
specified |! |
values — | | L
OK Goto© | | Goto
* page 64.20] | раде 64.23
Y Ds |
| window |
ок med
B-6
— To
| Driver's window operating switch,
7 | checking
— + ® remove control unit from door trim panel
( io e wire to left front window regulator
ANS motor routed through terminal T2
a tum on ignition
® measure voltage between terminals 3
— and 4, 5 and 4
\ e must read approximately 12V
- m connect tester to terminals 3 and 2
= lower window
e must read approximately 12V
|
Note
Voltage can only be measured while door
glass is being lowered.
|
\ | | ‚ m connect tester to terminals 3 and 1
| “| M raise window
e must read approximately 12V
Operating switches for right front, rear
window, checking
Note
Do not disconnect terminals from control
panel.
| ® turn on ignition
+ A ® measure voltage between terminals 3
and 4, 5 and 4
e must read approximately 12V - 5
E connect tester to terminals 3 and 2
E lower window
e must read approximately 12V
E connect tester to terminals 3 and 1
‘ E
/ O "WM raise window” TT TTT
| e must read approximately 12V
Go to
| E
page 64.21 |”
"Sema
B-7
Power wee i 64.20
‚Glass, Window Regulators
- am ee sen ==
ye |
Rear window safety switch, checking
Note
Switch must not be depressed. Do not
disconnect terminals.
Em turn on ignition
m connect tester to ground and terminal 2
e must read 12V
® connect tester to ground and terminal 1
e must read 0V
sm depress safety switch
E connect tester to ground and terminal 1
e must read approximately 12V
specified values NOT | specified values OK
OK >
B Y
= repair break in Go to Page
electrical wiring 64.22
or
m check operating
switches, safety
switch for
¥ continuity. Go to gi
Page 64.25 |
A
B-8
rower еле 64.2 ‚21
||
Glass, Window Regulators
A
A
B remove switch from door trim panel
® do not disconnect wiring
turn on ignition
E measure voltage between terminals 3
and 4, 5 and 4
e must be approximately 12V
=
m connect tester to terminais 3 and 2
E lower window .
e must read approximately 12V
® connect tester to terminals 3 and 1
® raise window .
e must read approximately 12V
E test rear window switches in same way
e safety switch in control panel must be
depressed
specified values NOT | specified values OK
OK window does not
- move
E |
# repair break in B repair wiring to
electrical wiring window regulator x
or motor, or replace
wm check switches window
for continuity. Go regulator. Go to
to Page 64.25 Page 64.23
End
B-9
Power inden opine 64.22
Glass, Window Regulators
Window regulator, checking
EN remove door trim panel
E reconnect window operating switch
| ® loosen regulator mounting bolts
=== = start engine
‚ = ‘ Bm depress switch to lower window
a e use second mechanic to push glass
window moves dowr Fwindow.does not
o
move down“ —
Y Y
m unplug operating m replace window
switch > | glass regulator
m set window in
half-open
position |
Lan | Em adjust end stop | .
т
End
Y
Window regulator, replacing
@ remove regulator mounting bolts
e door trim panel removed
® remove mounting bolts for regulator
- ® pull off terminal connector for window
regulator motor (arrow)
® withdraw regulator from bottom
® reinstall regulator in reverse order
® with ignition off, set glass at half way up
position and adjust end stop
+ Y
о End
eng DE : В | во
Window regulstor, checking GA 23
ВН Glass, Window Regulators
; | Window regulator operating ;
| switches, replacing
_ — 8 pry out from door trim panel
3 3 E pull off terminalsconnector
=
4
Driver's door control panel switches.
8 pry switch from panel at points shown
(arrows) 7
S push switch out of panel from bottom
Right front, rear window operating
switches
= pry out of door trim panel
B reinstall in reverse order, noting:
— ® switches are pressed in until “click
ished
Safety switch, removing/installing
TT
Removing Th …
| >
m remove control panel from door >
8 puli off terminal connector
S insert small screwdriver at arrows and
“ twist slightly
e press switch out at same time
Installing
m install in reverse order, noting:
e push switch in until “click” is heard
B-11
| Window regulator: operating switches, removing/Installing 6 4
Satety switch, removing/installi ng .24
: a | | Glass, Window Regulators
Window regulator operating Switches,
checking continuity
в remove switch
-® pry out .
- a pull off terminal connector
Mm connect tester to terminals 5 and 2, then |
3 and 1 | |
e specified value 0 ohms
| Mm connect tester to terminals 4 and 2
- e specified value » ohms
® operate switch to lower window
e specified value 0 ohms -
mM connect tester to terminals 4 and 1
e specified value © ohms
® operate switch to raise window
e specified value 0 ohms
specified values NOT | specified values OK
OK |
Y ;
E replace End
operating switch |
Y
> © ; | End,
IE | В | | Safety switch, checking continuity
| | ~~ | | @ remove driver's door control panel
mess —— ® connect tester to terminals 2 and 3 -
t EH Tha | | e specified value » ohms A
E—9 NE | | = push button in | a
_<> < FH — e specified value 0-ohms
i — ol |, — Че «т у
— | ce ; specified values NOT} specified values OK
LÀ |
a | Y
J и y pesa pan
- ul replace safety , | End
, o ~~ | - Switch |
End |. = —. =
| 7 = | . “ a ' Lo .
м | e | |
‘Window lato perating switches, safety
roi switch, checking continu 7 64.2;
+ A
; Co Glass, Window Regulators
| E 5 Thermofuse, location .
: > On left side of auxiliary refay pane! (arrow).
- =
"еее!
B-13
тесак 64.26 |
~~ CONTINUED IN THE
— BEGINNING OF. NEXT ROW -
© ma UN
Grommet stop — eN
CAUTION
Part numbers are for reference
only. Always check with your
Parts Department for latest
parts information.
Tab
Glass, Window Regulators
Window regulator assembly,
inspecting
\
Note 1
Before replacing/repairing window regulator
components, check window switch, electrical
wiring for proper function.
E remove door trim panel
® inspect the following
Regulator drive cable
If cable broken or frayed, window regulator
drive cable assembly must be replaced. Go to
page 64.39 8 .
Lifter pivot
If tab broken or loose, reattach with modified
swivel pins. Go to page 64.38
Grommet stop
Replace if missing or cracked,
Part Number 443 837 486
Electric motor mounting bushing
Replace if split or broken,
Part Number 431 133 741
C-2
Window requiator assembly, inspecting 64 " 27
CAUTION
Part numbers are for reference
only. Always check with your
Parts Department for latest
parts information.
CAUTION
Disassemble window regulator
motor on clean work surface.
NO dirt or dust must enter
motor. $
Relubricate with grease
G 000 450 02 or
equivalent as required.
Glass, Window Regulators
Window regulator motor/
disassembling
Note
Before disassembling window regulator motor,
check window switch, electrical wiring and
mechanical portion of regulator assembly for
proper operation.
® remove door trim pane!
remove inner door panel
m remove regulator mounting bolts, and
remove regulator trom inner door panel
# pull off terminal connector for regulator
motor (arrow)
o
® with regulator removed from door assembly
“ # clamp housing cover and plastic bearing
cover together with tie-wraps as shown
(arrows)
C-3
-
Window reguiator motor, disassembling 64 в 28
Glass, Window Regulators
—
: >
VT DOr SF
>. 7 A e mM
> °c
RAN A A
| La 7
“YES
ts > | 96-481 |,
>
>
# rémove mounting bolts securing motor to
drive cable housing (arrows)
M using a rocking motion, carefully separate
drive cable and cable spool from motor
e do not damage mating surface
E lift out vaned drive gear and set aside
® clean any corrosion from shaft (arrow) with
fine grit (400) sandpaper
m lubricate shaft with small amount of water
repellent grease G = 000 450 02 or
equivalent
Ca
Window reguiator motor, disassembing 64 „29
Glass, Window Regulators
E remove two screws and square washers
(arrows)
мой
Tr
ms carefully pry apart motor and gear housing
(arrows)
e use thin blade screwdriver, if necessary
® remove white plastic carbon brush holder
from motor housing (arrow)
y
cs
Window reaulator motor. disassemblina 64 «30
Glass, Window Regulators
"CAUTION a Window regulator motor,
| inspecting/cleaning
Do not scrape or use any
abrasives to clean carbon о m cliean contact surfaces on carbon brushes
brushes. | | (arrow) with electrical contact cleaner
| spray
e commercially available
E dry with compressed air
® remove armature from motor housing and
inspect armature
Note
if front armature bushing is seized to .
armature (arrow), proceed as follows:
«= carefully remove bushing
® remove any burrs from armature shaft and
inside of bushing
m reinstall bushing into gear housing
CAUTION
Do not use any abrasive
materials on commutator ог
brushes.
p> = clean commutator (arrow) with pencil
| eraser | | |
® clean between commutator segments with
a wooden toothpick
A
`
C-6
Window regulator motor, 6 4 -
Inspecting/cleaning a 31
Glass, Window Regulators
oe
m iubricate shaft at A with G 000 45002
>
or equivalent
am clean inside of motor case B with
Brakleen*.or equivalent
m blow dry with compressed air
Window regulator motor,
reassembling ,
Reinstall all window regulator motor
components in reverse order of removal,
© noting the following:
¢ install brush assembly on commutator
e slide armature with brush assembly into
motor housing |
e .attach motor to gear housing and install
vaned drive gear
a reinstall regulator motor to drive cable
>
assembly
e apply slight amount of grease to secure
gasket a when installing LD
4
5
* a
u if regulator motor and cable drive assembly
cannot be fitted together move cable carrier
slightly (arrow) |
® do not turn screw A for upper window
>
stop
8 reinstall-and tighten mounting bolts |
diagonally in numerical order as shown
e 3 Nm (2.2 ft 1b)
>
a
Nour
ZN
A
A,
и
С
N У
y
5
e
1
wy
q
|,
| ESS, a
64.32
Window reguiator motor, inspecting/Cieaning
Window regulator motor. nbiling
Glass, Window Regulators
® connect regulator assembly to power
supply
E operate motor in both directions
E if motor is noisy in one or both directions,
proceed as follows: -
® loosen two screws securing motor to
gear Housing
e gently twist motor housing back and forth
while operating motor
. e retighten screws when motor is operating
| the quietest
EM Cut off excess length of tie-wraps to prevent
getting caught in window regulator
E reinstall window regulator and door panel
E test window for proper function
C8 .
Window regulator motor, reassembling 64 e 33
Y
Glass, Window Regulators
CAUTION
Part numbers are for reference
only. Always check with your
Parts Department for latest
parts information.
CAUTION
Disassemble window regulator
on clean work surface.
NO dirt or dust must enter
motor.
Relubricate with grease
G .000 450 02 or
equivalent as required.
CAUTION
Do not remove tie-wraps after
completing repair.
[>
>
3
Window regulator motor/replacing
Note
Before replacing window regulator motor,
check window switch, electrical wiring and
mechanical portion of regulator assembiy for
proper operation.
Parts required
Audi 80/90 A
Description my. | Part number Quantity
Front left — |1988- 893 953 801D 1
Front right 11988- 893 953 802 Di 1
* Rear lefvright window reguiator motors cannot be
replaced.
mM remove door trim panel ;
# remove inner door panel o
® remove regulator mounting bolts, and
remove regulator from inner door panel
E pull off terminal connector for regulator
motor (arrow)
= with regulator removed from door assembly
clamp housing cover and plastic bearing
cover together with tie-wraps as shown
(arrows) `
|
———
| Window reguiator m ‚о рас 64.34
XE LU E.
YX MÁ
7 pe) A I Pu
RUE
ECS
ZZ > | 96-481 |,
>
Glass, Window Regulators
mM remove mounting bolts securing motor to
drive cable housing (arrows)
m using a rocking motion, carefully separate
drive cable and cable spool from motor
® do not damage mating surface
.
7
—. mM remove plastic dust cover from new
regulator motor ВЕ
® three vaned plastic drive gear and
. gasket remain on motor
a
. | po -
C-10
Window regulator motor, replacing 64 «3D
CAUTION
Vanes must fit securely into
drive cable housing.
>
>
>
+
Glass, Window Regulators
&
m carefully lift vaned drive gear from new
regulator motor (arrow)
e black rubber plate and ring gear stay
inside motor housing
/
& /
/
- * . - f
u insert vaned drive gear into drive cable /
housing (arrow) as shown /
. > /
/
7
. o
à
E reinstall new regulator motor to drive cable
assembly y
e apply slight amount of grease to secure
gasket a when installing
car
% -
=
> Window reguiator motor. repiacing 64 „36
+4 k <
Glass, Window Regulators >
> “a ¡f regulator motor and cable drive cannot
| be fitted together move cable carrier
slightly (arrow)
® do not turn screw A for upper window -
stop | . té
+
X 3 a
E reinstall and ima mounting bolts
diagonally4h numerical order as shown
e 3-Nm (2.2 ft Ib)
E Cut off excess length'of tie-wraps to prevent
> —.... Mfemove rubber hex bushin |
A
en
WENN a 9 . - ;
. | о я | | | Window regulator motor, replacing 64.37
TE ERE
Glass, Window Regulators
Window lifter pivot, repairing
area ia | | „—— Groove » ® modify two swivel pins, Part Number
"TT | 111 129 921 by cutting a 2.0 mm (5/64 in.)
groove in middle (as shown) with a
tungsten carbide rod saw or equivalent
e coat screw A with Loctite
» a install lug in cable guide
E insert modified swivel pins on both sides of
cable guide (arrows)
” » E move pins (arrows) up to cable guide, and - |
tighten screws , |
E check window regulator for proper function
5
co o | C13
“ Windowiifter pivot. repairing 64 38 a
Tw
Glass, Window Regulators -
CAUTION | Window regulator drive cable
Part-numbers are for reference assembly, replacing
only. Always check with your
Parts Department for latest
parts information. Before replacing window regulator motor,
check window switch, electrical wiring and
Note
mechanical portion of regulator assembly for
CAUTION | | proper operation. ; j
Disassemble window regulator . : |
assembly on ciean work ,
NO dirt or dust must enter : | Audi 80/90
motor. to -
— Relubricate with grease | Description | m.y. | Part number | Quantity
G 000 450 02 or Regulator |
equivalent as required. drive cable
assembly *
Front left — |1988- 893 837 397B | . 1
Front right |1988- 893 837 3988 1
* Rear leftright window reguiator motor drive cable
assembly cannot be replaced.
Em remove door trim panel
Em remove inner door panel! --..
Mm remove regulator mounting bolts, and
remove regulator from inner door panel
= pull off terminal connector for regulator
motor (arrow) ,
‘Da not remove tie-wraps after
completing repair.
= with regulator removed from door assembly
a clamp housing cover and plastic bearing
cover together with tie-wraps as shown
(arrows) |
Window regulator drive cable assembly, replacing 64 «39
; ,
4
4 Y
| - > ® remove mounting bolts securing motor to
; drive cable housing (arrows)
> 7) / = Tm
G E
ED 27 G
Y |
> |
LC 7 NO Y
> в using a rocking motion, carefully separate
é drive cable and cable spool from motor
e do not damage mating surface
> ® reinstall replacement window regulator
drive cable assembly onto motor
¢ apply slight amount of grease to secure
gasket a when installing
— 15
Window requiator drive cable assembly, осно 64 „40
+
4 “
> ass n ow e Ц а
'
LE ER EE AA 4 y Brad Bag Mos haf bes by med ded Ws An ee ur Rees Ba errr INIT OW Ber Mea MEW Blades Aug hey bm had Ws ba ms ко ke a rd rd Bea RAL Be Bay mes Rey Re ba dem Ke me = со
PE -
> = if regulator motor and cable drive cannot ’
be fitted together move cable carrier
slightly (arrow)
® measure stop screw A on old regulator aN
assembly and adjust stop screw on °
replacement regulator to same length
> ® reinstall and tighten mounting bolts
diagonally in numerical order as shown
; © 3 Nm (2.2 ft Ib)
-B Cut off excess length of tie-wraps to prevent
— getting caught in window regulator
Note .
Before installing window regulator into
vehicle, test function by connecting window -
regulator to 12V power supply, and operate in
both directions.
® reinstall window regulator and door panel
E test window for proper function
C16
Window regulator. drive cable assembly, replacing 64 «41 |
Cre MA a O a wey
“a ra MA AN Oy Rea ay
1
Glass, Window Regulators
Window replacing, general
information
To replace windshield, rear window or side
windows, the following tools and materials are
required.
Tool Kit VW 1474
1 — Reel
2 — Relay roller with holder
3 — Awl
4 — Guide rail
5 — Protective sheeting
6 — Wedge
Use protective sheeting VW 1474/7 to protect
‚instrument panel.
Tool kit VW 1351
e for removing broken windshields, rear
windows and broken or unbroken side
windows
CAUTION
To prevent paint damage, mask
perimeter of windshield, Year and side
windows with cloth duct tape.
A
a e -caulking gun *
® double suction pad (only for rear window,
windshield)
® protective goggles
e utility knife
e protective gloves (leather)
® cloth or duct tape
D-2
Co Window replacing, 6 4.
“pe general information 42
Se,
Glass, Window Regulators
Parts required ‚
CAUTION
Part numbers are listed for reference
only. Always consult with the Parts
Department for latest information.
Description Part number | Quantity
center spacers 895 845 237
for windshield 443 845 2370
adjusting wedges | 839 845 631A
for rear window
cutting wire 50m | 443 845 955
(150 ft) roll
‘adhesive kit D 004 300 03
(vehicles with
airbag) Y
adhesive kit - | D 004 300 04
(vehicles without
airbag) =
Mixing rod (For | D 009 700
use with adhesive]
kit D 004 300 04)
Hardening of adhesive sealing compound
[=
Vehicles without airbag &
a vehicle must stand at least one hour,
room temperature of 20°C (68°F) and
at
relative humidity of 65-70% before allowing
vehicle to be driven
Vehicles with airbag
a vehicle must stand at least three hours, at
room temperature of 20°C (68°F) and
relative humidity of 65-70% before allowing
vehicle to be driven
m keeping the sealed/bonded area wet forms
a skin that promotes hardening process
pd a a a .
D3,
уч `
a -} Window replacing
Le: Coupe general information
64.43
Glass, Window Regulators
Surplus bonding/sealing compound,
removing
CAUTION
When using any cleaning agent, follow
all cautions and warnings listed on the
containers.
A first use dry cloth to clean off painted areas
Mm excess adhesive sealing compound can be
removed using a cleaning solvent such as
supplied in repair kit
® do not use cleaners which contain
alcohol
® to clean plastic trim, let adhesive sealing
‘compound harden two to three hours, then
scrape off excess with plastic wedge
Sealing leaks
CAUTION
While adhesive sealant is hardening,
avoid putting pressure on glass from
inside car when cleaning around glass.
Mm water test window area before reinstalling
moldings, trim or lip or rubber molding
в агу area around leaks with compressed air
and clean
= apply adhesive sealant from outside to leak
area between glass and flange then
smooth over
um Totest area for water leaks |
. _ o
Note =~ a
The small adhesive sealant cartridge
D 009-100 03 is recommended for resealing.
BN
D-4
; 7] “Window replacing,
Coupe _ general repacino > 64.44
Glass, Window Regulators
Windshield, removing
# remove outer/interior A-pillar trim
(see Repair Group 70)
# remove beading from headliner
# remove windshield wipers
# remove plenum chamber cover (as shown)
® turn clips 180°
® disconnect wiring for front antenna
WARNING
Body flange Always wear protective goggles and
leather gloves when removing and
installing windows.
-
Molding with rubber tip
Windshield |
E remove inner rear-view mirror
d (see Repair Group 68)
GL > m cut off approximately 8m (26 ft) cutting wire
; E Cutting wire ® locate center of cutting wire
| ® on the outside, starting at top center of
windshield, press cutting wite under rubber
molding so wire runs completely around
perimeter of windshield ending at bottom
center
+ Adhesive sealant
54-175
| 3
!
t
CAUTION
Do not bend or twist wire, otherwise wire _
will break when under tension.
7.
> ® from inside push awl through adhesive
sealant at lower right corner (as shown) .
"until -awl eye is visible from outside”
® turn awl slightly and thread in one end of
wire A
E bend over wire and pull through to inside of
‚vehicle o
® do same at lower left corner with other end
of wire | |
-® remove guide rail
D-5
’ | | I Coupe ] Windshield, removing 64.45
Glass, Window Regulators
A
CAUTION
Ends of wire must be in adhesive
sealant as close together as possible,
but must not overiap, otherwise glass will
break or wire will bend or twist.
mM attach relay roller with holder into left and
right lower corner of windshield
e holder must support on dashboard
(arrow)
® attach reel (as shown) to center of
windshield
E guide wire up from base of windshield and
around relay rollers then thread ends into
reel
m slightly tension cutting wire with reel ande-
ratchet
® check that wire is placed correctly around
corners and molding | before cutting
E start cutting and continue cutting operation
until relay rollers are clear -
Note
If wire breaks in lower area, turn roller so
there is a sharper cutting angle. Continue
cutting with one wire up to A-pillar. In middle,
if there still is approximately 30 mm (12 in.)
adhesive compound left, turn roller and
continue cutting until all adhesive is removed.
mM remove relay rollers
m cut out windshield completely
2 ©
Note
If cutting wire breaks several times (wire gets
caught on the windshield flange) and can no
longer be fitted on the reel (wire too short),
cut remaining area with-tooi VW 1351 (pulling,
handle and mounting).
~ CAUTION o
Depending on extent of paint damage in:
removing windshield, touch- “up or repaint
- as required.
e
D-6
_Coupe Windshield, removing 64 a 46 |
Glass, Window Regulators
Windshield, installing
If windshield is to be reused, cut away
enough old adhesive sealant with utility knife
around glass and body flange to give smooth
uniform surface.
If body repair has been done, body flange
must be cleaned and primed with primer from
adhesive kit. ›
MM attach molding around windshield
m clean edge of glass approximately 30mm
(1-11/64 in) wide with cleaning solvent and
wipe dry with lint-free cloth
Ceramic black-out band around windshield is
not primer. Before applying adhesive sealant
prime this area with primer D 009 200.
®m cut applicator head
® insert felt into applicator head
wm thoroughly shake bottle of primer
(approximately 30 seconds) and fill
applicator bottle
Bm attach application head onto bottle
= apply primer a = 17mm (43/64 in) wide
evenly all around edge of windshield in one
continuous operation. Ensure applicator
head is always completely saturated
® drying time approximately 10 minutes
Note
Do not retouch strip of primer until it has
“dried completely.
WARNING
Adhesive used in bonded window glass
“ installations, original or replacement, -
may give off toxic fumes when heated.
Read container labels. Ensure adequate
ventilation. В
0-7
: : Соире Windshield, Installing 64.47
Glass, Window Regulators
> ®m apply adhesive sealant around windshield,
b - making sure that the adhesive sealant
— | touches the edge of the windshield
; A
«тест NE M PR b — 8 mm (5/16 in)
= 8 mm (5/16 in)
12 mm (15/32 in)
— ВЕ с
4 o d
’ — € SF Note 0
Reduce the height-of adhesive by the
It |
thickness of the adhesive remaining on the
windshield or the windshield body flange:
\ % | |
ir ` #
> ( |
‚68
: = Ne | ‚Coupe Ч Windshield, installing ‘ 64.48
Glass, Window Regulators
> Center spacers, instaliing
Top
m remove paper backing from spacer (self
adhesive)
® apply spacer in center of trim strip (as
shown)
1 — windshield
2 — trim strip
3 — spacer
4 — adhesive bead .
> Bottom
m remove paper backing from spacer (self
adhesive)
® apply spacer on center of windshield,
25 mm (1.0 in.) from lower edge of glass
1 — trim strip
2 — windshield
3 — spacer
4 — adhesive
> | 164-255 ® place windshield into position using two
: : double suction pad holders
a align windshield at the sides
> “insert adjusting wedges 1 into corners of
windshield (as shown) |
e wedges do not have to be removed
> ® align windshield gap f at top to 4-5 mm
(5/32-13/64 in.)
® lightly press windshield into place
~ ® press windshield at top until windshield
molding is flush with roof
® test for leaks
E clean off surplus adhesive sealant from
body and glass ,
® reinstall trim piece
— | CAUTION
| J Vehicles with airbags must stand at
47 | least three hours, at room temperature
of 20°C. (68°F) and a relative humidity of
| | 65-70% before allowing vehicle to be
AA =. | driven. |
a
| Vehicles without airbags must stand for |
at least one hour. oo 09
— —_— —_— о —— о LM. —
== maana nea
, | coupe | Windshield, Instaling. 64.40
~ Glass, Window Regulators
Side window, removing ;
® remove C-pillar trim, automatic seat
mounting, see Repair Group 70
m remove door weatherstrip in area of
B-pillar trim
Mm remove outer B-pillar trim 2, see >»
Repair Group 66 -
o
1 — pop-rivet
2 — B-pillar trim, outer
3 — support ,
4 — sleeve
5 — washer
6 — seal
7 — washer
8 — lock nut
5 Nm (3.7 ft Ib)
— 9 — screw/washer No
10 — support
® remove protective covering prior to
installing
Side window, installing
Install window in reverse order of removal,
noting the following:
E test window for water leaks
“D-10
Coupe Side window, removing/installing 64 «50
der
a
.. A
a .
af a
! +
1
_ - м!
+
.
D-11-
-
“ Glass, Window Regulators
Sp
“=
| EE
MEN Ж На a
Power window, troubleshooting q
- “Test conditions /
"| click audible no “click” audible
—/ т
7 Goto
Note
Refer always to appropriate wiring. diagram.
- © battery OK
Tools required
® multimeter US 1119
e LED tester US 1115
® test adaptor VW 1594
® sun VAT 40 or VAT 60 or equivalent with
current test lamp
No window operates
E, switch ignition ON
operate driver window switch
control unit OK
E listen for “click” sound from contro! unit
e indicates wires, relay, power supply to
o.
‘page 64. 52 |
. daa
No power to control unit
H 8 1 1 .
“ ES TER E НЕ >, w# remove left lower instrument panel cover
mn ee # pull control unit from auxiliary relay panel
he | # set multimeter to volt scale and connect
| * to terminals 14 and 2
as e must be 12V
»_, | € connect and read between terminals 14
and 1
. | ® turn ignition ON ;
В | e must be 12V- minimum
NOT OK “| OK window does
not operate —
5 - | m repair break in Go to
— electrical wiring (a
| or page 64.52
_ |= replace circuit 5
breaker (see . |. > 7
° 64.59) ——1 End I
BR _— 0-12
Соире Power window regulators, troubleshooting 6 4 5 1
a
- № window operates
Glass, Window Regulators
Ne
1
Checking front door contact switches
E switch ignition OFF
mM passenger door open
E multimeter US 1119 set to ohms scale
® connect multimeter to terminals 14 and 3
e must be 0 ohms
m press right front door contact switch
e must be = ohms (infinite)
mM driver door open
M connect multimeter between terminals 14
and 6 `
e must be 0 ohms
u press left front door contact switch
e must be = ohms (infinite)
NOT OK OK
| |
я repair break in ® reinstall control
electrical circuit unit
Y Y
LA ЧАР — TA —-Go-o-— ELIT E
page 64.54
° 2-13
64.52
Power window regulators, troubleshooting
п No window operates
Glass, Window Regulators
One window not working
Window. regulator current draw, checking
(installed)
> 8 connect voitamperage tester
Sun VAT 40, or VAT 60 or equivalent
e Sun VAT 60 shown
= connect inductive pick-up to battery
ground strap
® switch ignition ON
E press operating switches for window
regulators one after the other (open or
close)
8 measure current draw during window
switch operation
e must be 6-12A (during window travel)
Note
The tester will always indicate a certain
| current reading when the ignition 15
switched on; this reading will vary according
to operating conditions and the type of
model and equipment, to correct:
E zero tester to compensate for other
electrical consumers
SEs сене orem em after glass is at top or bottom and switch | =
depressed, current must be between
15-20A (stall current)
specified readings tester registers stall. Pp
NOT obtained; . current and window
window motor ñot glass does not move |
drawing current
ВЕ "NOT OK current OK
ный greater than | 0 Amp window
ОА 1 |
| Le 0 move
2 | or Breaker a у
| Trips — Go to Goto
Y | ® page 64.57 |
locate short page 64.54 | — x
circuit to. | —
ground ue |
‘according to ol OK |
wiring НЫЕ Ï
a. diagram window regulator —
. - ; | motor and circuit +] End
+
*
One power window not working, checking , 64.53
Glass, Window Regulators
[Window switch, checking
switch ignition ON
4 (+) andS(—)
e see illustration 96-950 for driver door
window switch, for passenger door
switch see 96-951
remove switch panel from door trim panel
set multimeter US 1119 to volts scale
connect and read multimeter between
terminals 4 (+) and 3 (—); then terminals
e must read approximately 12V
| \
|
|
i
NOT OK OK, window
inoperative
Y Y
> check power and Go to
ground wires of ©
| switch according to window switch
current flow ON, checking
diagram page 64.55
_ - . . A . - — +
9
D-15
|
Coupe
Power window switch, checking 64 в 54
Glass, Window Regulators
7
Window switch ON, checking
e see illustration 96-950 for driver door
window switch, for passenger door
windows see 96-951
© ignition ON |
> e window switch panel removed from
door trim panel
e multimeter US 1119 set to volts
æ connect and read multimeter between
| terminals 3 (—) and 2 (+) while lowering
window (holding switch in window down
: position)
e must be approximately 12V
wm connect and read multimeter between
- | terminais 5(—) and 1 (+) while raising
window (hold switch in window raising
position) |
e must be approximately 12V
Note
Window travel time should be approximately
8-10 seconds.
ome Ш ————————]——————— CT: TTT E IO a mon OK TES “NOTO = еее K AL. EA
_Y EE
> a | Goto | | Со 10
раде 64.57 раде 64.59
N
9
- - CO ps
» ;
Coupe Power window switch, checking 64 «55
Glass, Window Regulators
”
+
Driver's window switch, one-touch down
function, (driver's door only)
e door window in up position
® tum ignition ON
> u set muitimeter US 1119 to volts scale
u connect multimeter US 1119 between
terminals 3 (©) and 2 (®)
mM touch window switch for driver's door and
release, while observing multimeter
e must be approximately 12V as window
lowers
Note
Window travel time should be approximately
8 to 10 seconds. |
| NOT OK OK but window does
not move
Y Y
Go to Goto
page 64.51 |
page 64.54 |
D7
| Coupe — Switch one touch function, checking 64 156
Glass, Window Regulators
î
Window regulator, checking
® remove door trim panel
® reconnect window operating switch
® |[oosen regulator mounting bolts
® ignition ON
® depress switch to lower window
® use second mechanic to push glass
down |
window moves down | window does not
i move down
\ | 1
® unplug window | ® check wiring from:
switch . switch to
E set window in - regulator motor,
haif-open replace motor if
position > no wiring
® adjust end stop problems are
| found and
regulator is not
End bound
EE EE mea aw
Window regulator, replacing
m remove regulator mounting bolts
e door trim panel removed
| 8 disconnect terminal connector for window
regulator motor |
m withdraw regulator from bottom
m reinstall regulator in reverse order
- | # with ignition off, set glass at half way up
pôsition and adjust end stop
End
у
- —] AT e не py {rp mga 3, med, emma am вю сте бо. же окт = жиз толь вет A A
_
%
6-18 — Ё
Pas Wind lator, check!
Coupe ow rope ’ cmo 64.57
Glass, Window Regulators
Window switches, replacing
® pry out from door trim panel
E pull off terminal connector
Driver's door control panel switches
E pry switch from pane! at points shown
(arrows)
® push switch out of panel from bottom
Right front, window switch
m pry out of door trim panel
® reinstall in reverse order, noting:
® switches are pressed in until “click”
is heard
*%
©
= mst matin sam tits “оо мне 0 ts 08 apn — E Lucas зн a wm mee
Window operating switches, removing/installing | 64 a 58
Glass, Window Regulators
1 read between terminals 5 and 2, then 3
.
` 4
` cay т
. ro
1 mm.
7
e
Window regulator switches, checking
continuity
m remove switch
e pry out | .
® disconnect terminal connector from
switch
m set multimeter US 1119 to.ohm scale and
+
and 1
e must be 0 ohms
E connect multimeter to terminals 4 and 2
e must be = ohms (infinite)
B operate switch to lower window
e must be 0 ohms
m connect multimeter to terminals 4 and 1
e must be ©» ohms (infinite)
® operate switch to raise window
e must be 0 ohms
NOTOK OK
[I
m replace switch End
End
n,
- Circuit breaker, location
On left side of auxiliary relay panel (arrow). . -
D-20
~~
Window regulator switches,
- — checking contin "ty
Coupe | . Clreuit breaker, location d 5 64.00
12
Glass, Window Regulators
CAUTION
Part numbers are for reference
only. Always check with your
Parts Department for latest
parts information.
Window regulator motor, replacing
CAUTION
Disassemble window regulator
on clean work surface.
NO dirt or dust must enter
motor.
Relubricate with grease
G 000 450 02 or equivalent as
required.
CAUTION
Do not remove tie-wraps after
completing repair.
Note
Before replacing window regulator motor,
check window switch, electrical wiring and
mechanical portion of regulator assembly for
proper operation.
® remove door trim panel
E raise door glass almost to top
® remove regulator mounting bolts
# check and adjust window regulator drive
cable for equal tension on both sides of
motor 6
e check tension of springs (arrows)
E cut off tie wraps for mounting cables, wiring
harness
E remove regulator motor from drive cable
E pull motor downward and turn 180°
m clamp housing cover and plastic bearing
cover together with tie-wraps as shown
(arrows)
-D:217
‘ Window regulator motor, replacing 64 u 60 |
Glass, Window Regulators
® remove mounting bolts securing motor to
drive cable housing (arrows)
mM using a rocking motion, carefully separate
drive cable and cable spool from motor
e do not damage mating surface
® do not remove cable spool from drive
cable housing
E pull off terminal connector for regulator = —
motor (arrow) a | -
m remove regulátor motor from door
assembly ’ -
Glass, Window Regulators
+
Mm remove plastic dust cover from new
regulator motor
| “© three vaned plastic drive gear and
gasket remain on motor „ | |
-
re
Tag
ъ
Vaned drive gear
Dust cover
7 e ~~ Gasket
Y £4 A
ME =>
yl a
Motor — -
m carefully lift vaned drive gear from new
Vaned drive gear regulator motor (arrow) -
® black rubber plate and ring gear stay
inside motor housing ’
Black rubber
CAUTION
Vanes must fit securely into
drive cable housing.
mM insert vaned drive gear into drive cable
housing (arrow) as shown
D-23~ В | pe rotor 64
o В В Coupe Window regulator motor, replacing : „62
я = Glass, Window Regulators
m reinstall new regulator motor to drive cable
assembly
® apply slight amount of grease to secure
gasket a when installing -
e 4 tabs on vaned drive gear must engage
openings in motor
m if regulator motor and cable drive cannot
be fitted together move door glass up and
down
e 2 mechanics may be necessary
® reinstall and tighten mounting bolts
diagonally in numerical order as shown
e 3 Nm (2.2 ft ib)
2
@ remove rubber hex bushings from old
motor (arrow) and reinstall on new motor
m. cut off excess length of tie-wraps to prevent
getting caught in window regulator
m reinstall window regulator
® secure mounting cables and wiring
harnesses with new tie-wraps
® reconnect electrical connector
m reinstall door panel trim
m test window for proper function
ou muy 64
| Coupe — Window regulator motor, repiacing „63
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