Power Window Glass, Front - Comes Out of Track
9214vw01
Group: 64
Number: 91-04
Date: Nov. 30, 1991
Subject: Front Power Window Glass Comes Out of Track
Model(s): Passat from 1990 m.y.
Condition
Misaligned front guide rail (18) and bent rear guide rail (9) allow the window glass to move out of the front guide rail causing the lower arms of the regulator (11) to bend and come out of the lower slide rail of the regulator resulting in the glass tilting forward in the door.
Service
Refer to Group 70 of the Service Microfiche for specific removal/installation information on door trim items.
^ remove retaining screws on door trim panel edges
^ remove door handle cover and door handle
^ remove door release lever trim bezel
^ slide rearward in direction of arrow
^ disconnect power mirror connector from control switch
^ remove tipper door trim panel and disconnect power window control switch
^ remove power window control switch from door trim panel
Note
DO NOT damage the plastic moisture barrier, water leaks will occur if damaged moisture barriers are installed in the vehicle. Always replace damaged moisture barriers.
^ remove retaining screws for lower trim panel and remove panel disconnecting speaker electrical connector
^ push retainer pins into door on all door trim panel mounts and remove all mounts
^ remove door release lever assembly from door by sliding forward
^ CAREFULLY remove door plastic moisture barrier, taking care to NOT damage it
^ reconnect power window switch to plug and turn on ignition switch
^ lower window regulator until mounting bolts for glass are visible in holes 3, loosen bolts and remove
Note
If the regulator arms are bent the regulator may not move at all. Removal of the mounting bolts of the regulator may be necessary to lower the assembly low enough to loosen the mounting bolts for the window glass.
^ raise window glass to FULL UP position and tape glass in place
^ lower window regulator to approx. 1/2 down position
^ disconnect power window motor electrical connector
^ remove regulator mounting bolts (arrows)
^ remove window regulator/motor assembly
^ unscrew bolt on back of stop disc, 1 and remove disc noting position of stops on disc
^ remove motor mounting bolts (arrows) and motor
^ install motor onto new regulator with bolts
^ install stop disc onto regulator and secure with bolt noting proper position of stops on disc
^ recover push pins from door trim panel mounts inside of door
^ install window regulator into door with mounting bolts (arrows), noting retaining lugs positioned as shown
^ Torque = 7 N-m (5.2 ft.lb.)
^ connect motor power plug to wire harness connector
^ install black plastic guide arm (1) onto rear guide rail (2)
^ lower window regulator until window glass mounting holes are visible in large opening in bottom of door sheet metal
^ remove tape from glass and lower until glass is on regulator, mount glass to regulator with bolts loosely
^ fully raise window, then lower until bolts are visible in holes (3) and tighten
^ Torque = 7 N-m (5.2 ft.lb.)
^ lower glass with regulator until lower slide rail is visible in large opening of door sheet metal near bottom of door
^ insure that glass is in front guide rail
^ insure that black plastic guide arm is clipped onto rear guide rail
^ check for movement of glass front to rear
^ less than 5 mm movement
Note
If movement of glass exceeds 5 mm the glass will not stay in the front guide rail when raised. Check for bent or misaligned guide rails, the front rail may be replaced if necessary. Removal of the door glass, triangular trim piece and inner weather strip is required to replace the front window guide. The rear guide rail must be straightened in the door since it is part of the door sheet metal.
^ align guide rails as required to reduce movement of glass (front to rear) to 5 mm or less
Note
The lower mounting hole may have to be elongated to align the front window guide. The rear guide rail may need to be tapped rearward with a hammer or mallet. Touch up the elongated hole with touch up paint or an appropriate surface protectant prior to mounting lower bolt for front guide rail.
^ operate window at least 10 times up and down to insure proper alignment of glass
^ disconnect power window control switch
^ install plastic moisture barrier onto door insuring adhesion of plastic for a good seal to prevent water leaks
^ install door release handle assembly and foam seal
^ install door trim panel mounts and secure with push pins
^ connect speaker electrical plug to speaker, install lower door trim panel and secure with screws
^ install window control switch into upper door trim panel
^ install upper door trim panel
^ connect power mirror control switch to wire harness connector
^ install door release handle bezel into trim panel
^ install door handle
^ install retaining screws to door trim panel edges