Body - Rear Side Window is Inoperative
64 07 09September 20, 2007
2016012, Supersedes Technical Bulletin Group 64 number 07-08 dated Aug. 27, 2007 due to addition of power window setup
Vehicle Information
Condition
Window, Rear Side, Inoperative
Rear side window inoperative or will not roll up.
Technical Background
Window regulator cable retainer is broken. The material
of the retaining clip (POM) is too hard.
New material change was implemented to improve the
part flexibility.
Production Solution
Material modification to POLYAMIDE 6.6.
New cable retainer is identified by "polyamide 6.6"
Service
Remove rear window carrier plate, see Repair manual
group 64 Glass, Window regulators, in ElsaWeb.
Place window carrier plate on a clean and protected surface.
Note:
DO NOT remove the glass from the carrier plate.
DO NOT loosen adjustment bolts located above and below lower pulley.
Tip:
In an effort to save labor time, cut the original window cables as necessary. The cable housing will be replaced during this procedure.
Manually extend or retract window from carrier plate to gain working access to slider.
Remove the slider retainer nut and discard.
Lift cable retainer off of stud and discard.
Remove washer with tensioning spring and discard.
Remove slider base and discard.
Free window cables by cutting the tie strap
-arrow- at upper carrier plate support.
Carefully invert the window regulator assembly.
Remove the window regulator fasteners and separate
the window regulator from carrier plate support, see
Repair manual group 64 Glass, Window regulators, in
ElsaWeb.
Separate window motor from the original cable housing.
Tip:
A small flat screw driver may be used to separate the window motor from original cable housing.
Note:
Care must be taken when removing tie straps from new cable housing, prior to attaching the housing to the window motor. The cables are not spring loaded but may become misaligned if handled improperly. Should the
new cable housing loose its indexing see, Re-indexing Cable Assembly at the end of this procedure.
Remove the tie straps from new cable guide housing and place new cable housing on window motor.
Mount window motor to carrier plate using reference tabs and new screws from kit.
Tighten window motor in cross sequence to 3.5 Nm (31 in. lbs.).
Pass the cables through carrier plate support brace (as required).
Lubricate inside of slider base with Part No: G 000 450 02 and then place the slider base onto carrier plate guide.
Install new tensioning spring in lubricant.
Install 0.5mm washer on top of spring.
Fit upper and lower cable ends into new cable retainer.
Ensure cables are fully seated.
Tip:
Ensure upper and/or low cable is routed through carrier plate support brace as required.
Place cable retainer and new 1mm washer onto slider and tighten nut to 2.5 Nm (22 in. lbs.).
Tip:
The window and frame assembly may be manually extend or retracted to gain proper positioning of cable assemblies.
Route upper cable around upper pulley and seat upper cable guide into slot -arrow-.
Carefully position the opposite end of the upper cable onto motor.
Note:
The window must be retracted to its lowest position to compress the spring -arrow-.
This action will release tension from cables to ease installation onto pulleys.
Retract window and frame to gain maximum slack in cable assemblies.
Position window cable on to special tool VWM 100 (Window Cable Installation Tool and fit tool onto lower pulley.
Twist special tool VWM 100 until tool overcomes the upper cable spring tension and seats cable in lower pulley.
Care must be taken to ensure proper position of upper cable during this operation.
Use the notches in the lower pulley to assist cable installation on lower pulley.
Secure upper cable with tie strap -arrow-.
Tip:
The natural curve of the upper cable into the window motor assembly must be preserved.
Lubricate both carrier plate guides along the entire run of window with Part No: G 000 450 02.
Install and adjust rear window regulator.
Tip:
Perform rear window relearn procedure - use key in driver's door and run window full up and down.
See Repair Manual group 64 Glass, Window regulators, in ElsaWeb.
Re-indexing Cable Assembly
Seat the lower window cable in the cable guide groove.
Wrap upper window cable 3 times around the cable guide and insert the guide with cables into the cover assembly.
Ensure the upper window cable (heavy rubber sheathing) rides on top of the lower window cable (bearable), and the cable spring is located at the gear
housing, before positioning the housing onto window motor.
Tip:
Right side shown - left side is opposite where rubber sheathed cable is on the bottom of the bare cable.
Warranty
Required Parts and Tools
Additional Information
All part and service references provided in this Technical Bulletin are subject to change and/or removal. Always check with your Parts Dept. and Repair Manuals for the latest information.