Window Regulator, Disassembling and Assembling

Before removing, first determine whether the malfunction affects the cables, mechanical components or motor/drive gear.

This procedure is for replacing the motor/drive gear. It also applies for other mechanical components, except that the door glass upper end stop must also be checked and/or adjusted.

- Remove window regulator and door component carrier from door, then remove window regulator from door component carrier.

- Hold housing cover and plastic bearing cover together by installing tie-wraps at cable outlets (arrows).





CAUTION!
DO NOT remove the two tie-wraps at any time before repair work is completed or repair will not be possible.


- Remove drive cable housing cover screws (arrows).





- Using a rocking motion, carefully remove drive cable housing and cable spool from motor in direction of arrows.





- Be careful not to damage mating surfaces.
- Be careful not to lose the 3 damping elements, which may fall Out at this time.
- Remove plastic dust cover from new motor in direction of arrow.




Make sure flange seal and 3-vaned plastic drive gear remain in place on drive motor housing.


NOTE: Keep the motor clean. Do not get dust and/or dirt on greased surfaces and parts. If additional grease is necessary use only grease Part No. G 000 450 02.


CAUTION!
Part numbers are listed here for reference only. Always check with your Parts department for the latest information.


- Carefully remove 3-vaned plastic drive gear from drive shaft of new motor in direction of arrow.
Do not remove molded rubber plate from motor drive housing.





- Check motor/drive parts (molded rubber plate, damping elements, etc.) for damage and replace if necessary.
- Install 3-varied plastic drive gear into cable housing in direction of arrow.





CAUTION!
Make sure that the three damper elements fit properly into the recesses in the cable housing.


- Install motor onto cable housing in direction shown (arrows).




Make sure that the 4 lugs on the 3-vaned plastic drive gear align with the recesses in the molded rubber plate on the motor/drive housing.


NOTE: If necessary, use a thin film of grease to prevent the flange seal and drive gear from falling out of the motor/drive housing.


If motor/drive housing does not fully seat onto cable housing:





- Move lifting pivot back and forth (arrow) to change position of molded rubber plate until it engages.
Do not turn the upper end stop adjusting screw.

- Install housing screws and tighten by alternating in numerical sequence shown.
Tightening torque: 3 Nm (27 in. lb)





- Remove rubber hex bushings (arrows) from old motor, check for damage, and install on new motor.





- Tighten motor mounting nuts.
Tightening torque: 3 Nm (27 in. lb)


NOTES:
- Check motor operation before installing regulator assembly on door component carrier.
- Cut off excess length of tie-wraps to avoid scraping noises during window operation.