Service

Window regulator/cable assemblies can be repaired using special tool kit JC4100 and the appropriate procedure.

Regulator/cable assemblies should always be repaired unless carrier or cable pulleys have been damaged and must be replaced.

If cables or clamps are damaged, replace cable assembly and clamps.

In addition, replace clamps on opposite side (unless opposite side has been previously repaired using parts shown) using clamps from second kit (discard unused cable from second kit).

Special Tool JC4100





- J04100 tool kit contains:

^ Locking pliers (clamping tool).

^ Special cable removal/installation tools with various pin configurations for different cable pulleys (numbered 1 through 4).

^ Instruction Sheet.





^ Tool # 1, for removing and installing cable on all cam-faced pulleys.





^ Tool # 2, with long hook, for removing cable on all pulleys except cam-faced.





^ Tool # 3, for installing cable on two-notch and some one-notch pulleys with reinforcing rib that aligns with notch (arrow).





^ Tool # 4, for installing cable on one-notch pulleys with offset reinforcing ribs (arrows).

Window regulator, repairing





Parts required

CAUTION!
Part numbers are for reference only. Always check with your Parts Dept. for the latest parts information.

Identifying repair procedure

- Remove window regulator motor from carrier assembly, loosen carrier from door (see VESIS "Body Exterior" Repair group 64).

Note:
It is not necessary to completely remove carrier from vehicle to perform repair.

To allow carrier to be placed inside vehicle as shown at left:

- Disconnect mirror and speaker connectors.

- Reach behind carrier and pinch first and second wiring harness cable ties (arrows) and push through carrier (this gives enough slack in harness to pivot carrier to position shown).





- Place carrier assembly inside vehicle on a clean protective surface such as a VAS 5193 fender cover (as shown) to protect seat and interior trim and door sill trim.

- Check integrity of cables, clamps and pulleys.

If cables or clamps are damaged:

- Install Kit (cable assembly and clamps).

- In addition, on opposite side, replace clamps (unless opposite side has been previously repaired using parts shown) using clamps from a second kit (discard unused cable from second kit).

^ Prior to start of repairs:





- Protect speakers from damage. Install locking pliers (clamping tool) to regulator (to release tension on cables) when replacing clamps only.

- Identify type of pulleys (cam-faced, one or two notches, pulley reinforcement rib locations) and tools required for cable removal and installation.

Window regulator, replacing damaged cable assembly

Note:
To aid in demonstrating procedure, illustrations show carrier removed from vehicle.

- Remove cables from pulleys (to regulator only) using appropriate removal tool at both tracks DO NOT cut cables!





- Leave single cable (arrows) attached (cable is not replaced).

- Move window clamps to top of carrier (clamps must be at top of carrier to be removed).

Window clamp, removing from track

With clamps at top of carrier:





- Flip window clamp up (arrow) and remove from track as shown (noting cable placement).

- Disengage cable crimped ends from window clamp.

If replacing clamps only, (go to "Window clamp, installing on track").





- Remove regulator assembly (see "Regulator, removing from carrier assembly").

^ Single cable remains in installed position.

Regulator, removing from carrier assembly On opposite side of carrier:





- Using a small flat blade screw driver to press lock tabs on three mounting pins (arrows) inward while applying downward pressure to regulator with finger (as shown).

Note:
Note placement of foam isolator washers at each mounting pin location (may come off with motor).

New washers are included in kit and must be installed between window regulator and motor on final assembly of motor to regulator.





- Clean any grease and dirt from tracks and around regulator insertion hole (arrow).

^ Carrier assembly is now ready to install new cables.

Regulator/cable assembly, preparing for installation

- Remove three foam washers from assembly.





- Unfold cables, tie wraps (arrows) through center of assembly are removed later in procedure).

Note:
Orientation of tie wraps should be such that the locking block of the tie wrap does not interfere with installation of regulator to the carder assembly.

Regulator/cable assembly, installing

Note:
Slide long cable (from regulator) under single cable (already installed).

- Attach regulator to carrier by inserting three pins from regulator into the carrier assembly (pressing gently to seat).





- Slide cable sheathing ends into regulator (arrows).





- Insert short cable (from regulator assembly) into carrier assembly nearest speaker hole (black arrow), leaving cable loose (as shown) DO NOT route cable around this pulley at this time.

- Insert long cable into carrier assembly opposite speaker hole (white arrow), routing cable around pulley (use correct tool as necessary).

Note:
Cable ends must end up near top of regulator for insertion into A-Pillar clamp (clamp nearest the speaker).

A-Pillar clamp is always installed first and can only be installed at top of carrier.

With regulator/cable assembly installed onto carrier assembly:

- Install new clamps (see "Window clamp, installing on track").

Window clamp, installing on track

- Install window clamp on track and insert cable crimped ends in identical position as removed (not overlapping).

Note:
First cable is fitted into deep packet, then insert second cable into shallow pocket.





- Flip clamp down towards track.

- Install second window clamp (B-Pillar clamp) near the center of the track and insert cable crimped ends in identical position as removed (not overlapping).

Note:
First cable is fitted into deep pocket, then insert second cable into shallow pocket.

- With both window clamps installed on tracks





- Check the four plastic cable guide ends (black arrows) for correct engagement into housing.

With both clamps at middle of carrier assembly as shown (white arrows):

- Install cable on last pulley.

Cable, installing on pulley (notched pulleys)

- Install cable on last pulley as follows:

- Place cable over pulley.





- Insert correct installation tool pin (Tool # 3 or 4) into pulley notch (white paint mark on side of tool indicates correct pin).

With remaining pins of tool engaged into face of pulley:

- Rotate tool and pulley 3600 until cable is wrapped around pulley.

Note:
It may be necessary to rotate pulley an additional 360° to set cable into pulley groove.

Cable, installing on pulley (cam-faced pulleys)





- Place cable over cam on pulley as shown.

- Grab both clamps and slide to bottom of assembly (cable will self-install into pulley groove).

^ Use correct tool (as necessary) if cable will not self-install.

After installing cable on pulley

- Remove tie wraps from regulator.

- Install three foam washers on mounting pins on motor side of carrier.

- Carefully install motor assembly while holding cable housing assembly against the carrier.

Note:
Failure to hold cable housing assembly against carrier may allow housing to fall away from carrier, which may cause housing pulley to come apart.

- Remove metal clamp or locking pliers.

- Temporarily connect power and window switch to motor assembly and cycle regulator several times.





- Lubricate guides and track along full length, on top and underside of track (white arrows) on contact surfaces with lubricant Part No: G 000 45002.

- Cycle regulator again (several times) to verify proper function.

Prior to removing power:

- Move clamps to the proper window installation position (so fasteners can be tightened once window is installed).

New Beetle Models only:





- Install isolator pad (included in kit) onto regulator as shown (arrow).

All Models:

- Reinstall carrier assembly into door and reinstall window regulator motor onto carrier assembly (see VESIS "Body Exterior" Repair group 64).

- Check operation of power windows.

- Reset pinch protection as necessary.