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Home >> Volkswagen >> 2003 >> New Beetle (1C1) L4-1.8L Turbo (AWV) >> Repair and Diagnosis >> Windows and Glass >> Windows >> Window Regulator >> Technical Service Bulletins >> All Technical Service Bulletins >> Campaign - Convertible Top Button/Front Window Clamp >> Work Sequence >> Section A

Section A

Section A - Loctite Threadlocker Application and Front Window Adjustment





- Open door and insert flat blade of screwdriver between handle trim -1- and handle and carefully pry trim off handle





- Remove 2 screws -2- from behind trim -1-
- Remove 3 screws -3- at bottom of door trim panel -4-
- Using pliers tool 3392 unclip 6 retainers -6-
- Lift door trim panel upward and out of window slot seal





- Remove rubber grommets from holes -1- in the door inner panel

NOTE: Rubber grommet and hole at front position is smaller than rubber grommet and hole at rear

- Raise or lower window position -4- so the bolts -2- and -3- are visible through holes -1-
- Ensure that ignition switch is in the "OFF" position
- Open hood and disconnect ground (GND) cable from battery





- On door trim panel, unclip cable guide -1- using the flat blade of a screwdriver -2-, pull cable out of retainer -3- in direction of arrow and unhook cable hook -4-
- Disconnect electrical connectors to window switch, light, etc. and set door trim panel aside





- Loosen nut -5- but do not remove
- Remove T30 Torx bolts -2- and -3- (bolts on clamps holding window) and add two drops of Loctite Threadlocker Blue to bolt threads

NOTE:
- Be careful not to drop bolt.
- A magnetic Torx bit or small magnet can help in bolt removal

- Loosely reinstall Torx bolts -2- and -3-
- Push window -4- down to ensure it is fully seated into window clamps
- Slide window forward or rearward -arrow- until distance from rear edge of window to edge of door is 65 mm±1 (2.52 in. to 2.60 in.) -A-

NOTE: Only position in which distance -A- can be measured is when bolts on window clamps are visible through bolt access holes





- Tighten bolt -3- to 8 Nm (71 in. lbs.)
- Reconnect electrical connectors to door trim panel and reconnect ground (GND) cable to battery
- Lower window completely and raise back to previous position where bolts -2- and -3- are visible through holes -1-
- Tighten bolt -2- to 8 Nm (71 in. lbs.) then tighten nut -5- to 8 Nm (71 in. lbs.)

NOTE: The X - axis window adjustment has been completed. Check dimension -A-, if not 65 mm±1 (2.52 in. to 2.60 in.) adjust again

- Reinstall rubber grommets into bolt access holes
- Reconnect cable to door lever and clip cable guide in position





- Reconnect remaining electrical connectors to light, lock, etc.
- Reinstall door trim panel -4- onto the door and secure with clips -6-

NOTE: Check door trim clips before reinstalling door trim panel and replace as necessary

- Secure door trim panel with three Torx screws -3- along bottom of door and tighten to 4 Nm (35 in. lbs.)
- Secure door trim panel with two phillips head screws -2- and tighten to 4 Nm (35 in. lbs.)
- Reinstall handle trim -1-
- With door closed and window in the full up position, check to see whether window top rear corner is 1.0 mm (0.40 in.) outward of rear window glass

NOTE: This is the Y - axis window adjustment





- If window is not outboard 1.0 mm adjust glass as follows:
- On bottom of door at front and rear, remove rubber plugs covering nuts -A-
- Loosen nuts -A- and adjust window in/out position -arrow- equally to achieve the 1.0 mm outward window position and tighten nuts

NOTE: Sliding nuts outward brings window inward at the top

- Tighten nuts and replace rubber covers when window is in correct position





- Open door and place three pieces of tape along the top of the window as indicated in illustration -arrows-
- Close door and mark depth of window entry into window slot
- Open door; use a scale to measure window entry depth
- Depth needed is 8 mm±1 (.28 in. - .35 in.)

NOTE: This is the Z - window adjustment.





- Remove rubber plugs on bottom of door; use a T30 Torx driver and turn screw clockwise to raise window or counterclockwise to lower window to reach required depth

NOTE: By turning Torx screw one revolution, window will move 1 mm (0.04 in.)





- Turn ignition switch to "ON" position
- Push and release PRESS button -arrow 7- and pull locking handle down

NOTE: DO NOT pull on PRESS button

- Turn handle -arrow 4- counterclockwise until it stops, then push convertible top upward, open it slightly and release the handle
- Lift control switch and partially open the top





- Raise door window and rear window to top position
- Height -a- of both windows should be same; otherwise perform Z - axis adjustment
- Distance -b- (measured horizontally near top of windows) must be equal to 9.5 mm±0.5 (0.35 in. - 0.39 in.) otherwise repeat Z - axis adjustment

NOTE: Illustration is showing the left door window and rear glass

- Reinstall rubber plugs at bottom of door
- Repeat procedure on opposite door
- Tighten the ground (GND) cable to battery to 5 Nm. (44 in. lbs.)
- Perform power restoration procedure
- Proceed to Section B

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