3.2.3 Rear Door Window and Quarter Window Carrier Assembly
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- Clifford Walton
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1 Tighten all bolts. Tighten bolts marked -1- and -2- in specified sequence. Tightening torque: 8 Nm Remaining bolts can be tightened in any sequence. Insert door window -3- through window recess without additional force into clamping brackets and align at rear window guide -arrow-. While doing this, make sure that window stands parallel to window guide. Tighten clamping brackets with bolts -4-. Tightening torque: Plastic clamping brackets 9 Nm, aluminum clamping brackets 11 Nm. Then, perform in reverse order of removal. Then, perform a function load test Rear Door Window and Quarter Window Carrier Assembly Door window and quarter window are contained in following description Removing carrier assembly. Window regulator, door lock and loudspeaker are secured to carrier assembly. Window regulator is part of carrier assembly delivery casing and cannot be replaced individually. Carrier assembly can only be removed when door window is removed from window regulator. For this purpose, door window must be driven down to height of installation hole in carrier assembly and spreader pins must be removed. If it is not possible to drive down door window by electrical window regulator, first exact cause of malfunction must be determined. To do so, using Scan Tool (ST) -V.A.G 1551-, check DTC Memory of comfort system (address word 46), refer to Body On Board Diagnostic; Rep. Gr. 01 ; Diagnosis and Testing. If there is an electrical fault via window regulator motor, this can be removed from carrier assembly. Removing Removing rear door trim, refer to Body Interior; Rep. Gr. 70 ; Removal and Installation. Removing and installing lock cylinder housing, refer to Lock Cylinder Housing, page /18
2 Pry off cap -1-. Lower door window until spreader pin -2- and spreader plug -3- are accessible in window cut-out. If work step is not possible due to a malfunction via electrical window regulator, window regulator motor can be removed to be able to slide window down. Screw in a 5 mm bolt (approx. 70 mm long) into spreader pin -2- and pull out from spreader plug -3-. Now screw in a 8 mm bolt (approx. 80 mm long) into spreader plug -3-. When screwing bolt into spreader plug, do not use excessive force on anchor otherwise it may fall backward into door. Pull out spreader plug from window regulator guide and thereby from door window. During this, release cable must be pressed to side from window using a screwdriver. Pull off seal -1- from center bar up to window recess seal -2-. Pry off cap -3-. Remove visible bolt. 6/18
3 Using a screwdriver -1-, lift catch -2- and remove filler piece -3- upward out of window frame. Grip inner window recess seal -1- using pliers -2-. Then, move pliers in direction of -arrow- and simultaneously lift off window recess seal -1- from door flange using a light turning motion upward. For easier removal of window recess seal, pliers may be supported using a wedge /18
4 Slide door window -1- upward and remove inward -arrow- from door. Remove window guide -1- in upper area and remove bolt -2- at center bar. Bolt -2- is gradually being discontinued. Therefore, center bar is then clipped into door at top. Rest of work procedure remains identical. Remove bolt -1-. Remove center bar -2- from quarter window seal -3- and remove downward from top of window guide. Remove center bar -1- upward from door. 8/18
5 Remove window guide -1- from door flange -2-. Rotate lower area of window guide outward 90 -arrow A- and then remove window recess seal -3- upward -arrow B-. Now quarter window can removed from door at corner -arrow-. Carrier Assembly, Removing (continued) Remove boot -1- from B-pillar. Disconnect connector -2-. Remove bolts -arrows-. Remove bolt -1- (for lock). 9/18
6 Remove upper carrier assembly from door, lift and lift out of door toward hinge side -arrow- of door. Next, loosen two clips for electrical wire from reinforcement plate in door and disconnect wire from boot. Quarter Window, Installing Insert quarter window into door -arrow A- (soapy solution as a lubricant facilitates inserting). Attach window guide -1- onto door flange -2- from outside and rotate outward 90. Then insert window guide into window recess as depicted in illustration. Now window recess seal -3- can be pressed onto door flange downward -arrow B-. Position window guide -1- in door flange -2- and install completely. Then, perform in reverse order of removal. Carrier Assembly, Installing 10/18
7 Pull operating lever -1- in direction of -arrow-. Using a screwdriver, tension spring -2- secured to door lock in direction of -arrow- and engage lock lever into spring. Lock is secured by engaging operating lever. Thereby later incorrect clipping-in of release cable is prevented. Insert electrical wire through boot into door and secure clips in door plate. Insert carrier assembly into door. 11/18
8 Tighten all bolts. Tighten bolts marked -1- and -2- in specified sequence. Tightening torque: 8 Nm Remaining bolts can be tightened in any sequence. Installing door window, see installing door window at window regulator page, refer to Door Window, Installing on Window Regulator, page 207. Then, perform in reverse order of removal. Then, perform a function load test Door Window, Installing on Window Regulator Window must be checked for damage before inserting spreader plug and spreader pin. Spreader plug and spreader pin must always be replaced when performing installation work at door window. With window removed, insert spreader plug -2- centered. Press in spreader pin -1- flush into spreader plug -2-. Guide door window into door. Insert door window -3- into slit of window regulator guide -4-. Using light pressure from above, lock window into window regulator -arrow Window Regulator Motor or Carrier Assembly with Window Regulator Removing Illustration shows removal and installation of window regulator motor/carrier assembly with window regulator for rear doors. Removing and installing for front doors is performed in same way. Removing front or rear carrier assembly, refer to Carrier Assembly, page 197 or 12/18
9 3.2.3 Rear Door Window and Quarter Window Carrier Assembly, page 200. Slide a hammer handle between window guide and carrier assembly so far until hammer handle end presses on gears of carrier assembly. Remove bolts -1- and remove window regulator. Window Regulator Motor, Installing By removing window regulator motor, gearing shifts, it is not centered. When installing window regulator motor, gears must be aligned until window regulator motor is centered again. Attach and tighten bolts -1-. Tightening torque: 3.5 Nm Tightening torque must always be observed since otherwise damage to plastic sleeve on window regulator motor can result. Carrier Assembly with Window Regulator, Installing For replacement part carrier assemblys, gearing is secured against slipping and falling by a cable tie -1-. Slide a hammer handle between window guide and SF so far until hammer handle end presses on gears of SF. 13/18
10 Remove cable tie -1-. By removing window regulator motor, gearing shifts, it is not centered. When installing window regulator motor, gears must be aligned until window regulator motor is centered again. Attach and tighten bolts -1-. Tightening torque: 3.5 Nm Tightening torque must always be observed since otherwise damage to plastic sleeve on window regulator motor can result Window Regulator When servicing window regulator, following components can be replaced: Coupling plate with clamping brackets Cable reel with release cable Window regulator motor (for electrical window regulators) Window crank (for mechanical window regulators) Removing Removing carrier assembly with window regulator, refer to Carrier Assembly, page 197. Vehicles with electrical window regulators Removing motor for window regulator, refer to Window Regulator Motor or Carrier Assembly with Window Regulator, page 207. Vehicles with mechanical window regulators Removing crank mechanism and transfer element for cable reel, refer to page /18
11 Continued for all vehicles Repair using repair kit is only possible with window regulator that are equipped with eccentric relay pulley -1-. For window regulators with relay pulleys without eccentric -2-, complete carrier assembly must be replaced. Color of relay pulleys is not important. Protect loudspeakers against damage during entire repair. Place carrier assembly on a level surface, support if necessary. Checking relay pulleys, guide rails and seal for damage. Replace carrier assembly if damaged. Locate start and end of diagonal release cable -4-. Do not damage diagonal release cable -4-, this is not replaced. Release cables -2- and -6-, which come from cable reel -5-, must be cut through in guide rails -3- and -7-. Slide coupling plate and clamping brackets -1- on guide rails into topmost position. It is only possible to remove coupling plate with clamping brackets here. Fold coupling plate and clamping brackets -1- in direction of - arrow-. When doing this, note position of release cables -2- and -3- in coupling plate. Remove cut-off ends of release cables from coupling plates. Diagonal release cable must not be changed in its installation position. Removing crank mechanism (vehicles with mechanical window regulators Remove bolts -1-. Remove crank mechanism -2-. Remove seals /18
12 Remove transfer element for cable reel -1-. Continued for all vehicles Press together retaining clamps of threaded sleeves -arrows-. Remove cable reel from carrier assembly. Clean guide rails -1- and -2- as well as insertion opening -arrow- of grease and dirt. Installing Insert threaded sleeves -arrows- of new cable reel through openings in carrier assembly. Cut and remove both cable ties on cable reel. 16/18
13 Press cable reel -1- into carrier assembly using light pressure. Do not remove securing plate -2- from cable reel. Route release cable with long sheathing -3- under diagonal release cable -4-. Guide sheathing of release cables into cable reel -1- -arrows-. Guide release cable with short sheathing into release cable mount of front guide rail. Do not thread release cable onto relay pulley yet. Guide release cable with long sheathing into release cable mount of rear guide rail. Do not insert release cable onto relay pulley yet. Ends of release cable must be located in vicinity of upper side of window regulator because clamping brackets can only be installed on guide rails in topmost position. If necessary, pull release cable slightly out of cable reel. Installation of coupling plate with clamping brackets Connect coupling plate with clamping brackets sideways onto guide rail. Clamping brackets must face toward upper side of window regulator. Insert crimped release cable ends into coupling plate -3-. First insert release cable -1- coming from below into upper, deep groove. Next, insert release cable -2- coming from above into lower, shallow groove. Release cables must not cross. Fold up coupling plate with clamping brackets -1- in direction of - arrow- toward guide rail -2-. Install second coupling plate with clamping brackets -1- as described. Thread in release cable onto relay pulley 17/18
14 Check 4 ends of release cable sheathings for correct seating in mounts -arrow-. Route release cable -1- onto eccentric washer of relay pulleys -2- as depicted in illustration. All eccentric washers must be rotate to lowest height, otherwise it is very difficult to install release cable onto last relay pulley. Remove securing plate -2- from cable reel -1-. Pull both coupling plates with clamping brackets up to lower end of guide rails. When doing this, release cable slide automatically into relay pulley grooves. Check position of release cable. Release cable must be located correctly in groove at all 4 relay pulleys. Slide coupling plates with clamping brackets back and forth several times on guide rails to check them for proper function. Vehicles with electrical window regulators Place foam shims contained in repair set between window regulator motor and carrier assembly. Install motor for window regulator. Tighten bolts to 3.5 Nm. Vehicles with mechanical window regulators Connect transfer element for cable reel -1-. Insert new seals -2-. Connect crank mechanism -2-. If necessary, align transfer element for cable reel and crank mechanism. To do so, rotate transfer element as far until transfer element and crank mechanism have correct position to each other. Tighten bolts to -1- to 3.5 Nm. Continued for all vehicles Installing carrier assembly with window regulator, refer to Carrier Assembly, page 197. Slide door window into clamping brackets without excessive force and align to rear window guide. Tighten bolts for clamping brackets to 10 Nm. 18/18
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