Power Window Removal

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Lukas

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I followed Styria's "one photo tutorial" on power window removal 4 times this morning while dismantling the 450 a bit more, so thought I'd do a step-by-step for those, like me, who are new to that process.

It's the same sequence for front and rear, left and right, save the odd different step.

Tools: flat and phillips head screwdrivers, 10mm socket, possibly pliers for clip removal. Something to place under the screwdriver when prising out clips (to protect the paint).

  1. Remove door card (unscrew armrests, remove window switch, ashtray and door handle surround, lift card up).
  2. Remove exterior trim at base of window - prise up gently from latch end. Admire grime buildup beneath.
  3. Remove black felty trim in same location (prise up clips - watch the paint!) - can be left until later if desired, but must be done before glass removal.
  4. Lower window to about 5cm from bottom: either temporarily re-attach the switch to do this, or hook up plain (unstriped) black and green wires to 12v; green on + makes it go down
  5. Remove the black seal / felty lining from the top and sides of the window frame.
  6. The window and the horizontal rail holding it are attached by a bolt at either end - remove these carefully, being sure to catch the window and lower it to the bottom of the door cavity. Leave the middle bolt in the same line - that holds the bracket that attaches to the vertical guide rail.
  7. Remove bailey channel - the vertical strip with either the mirror (front door) or the rear 1/4 window (back door) on the other side of it.

    Front: remove black plastic mirror adjuster handle, unscrew triangular silver plate, unscrew mirror (smaller screws inside the metal frame), remove mirror; then remove phillips screw at top of channel and 2x bolts at base of mirror frame. Lift bailey channel out, twisting it to get the bracket out at the bottom - watch the glass! Lift the mirror frame out too. Remove the small bracket that is revealed below the mirror frame - 1x clip holds it on.

    Rear: unscrew phillips at top of channel and bolt in the door at the bottom. Move towards front of the car, and catch the rear 1/4 window when it comes loose. Lift the channel out of the gap.
  8. With bailey channels out of the way, lift the glass + rail up and remove from the door frame.
  9. Unscrew the 3rd screw that attaches the bracket for the vertical rail. Catch the bracket and the plastic (black or white) guide piece on the other side of the vertical rail.
  10. Remove the vertical rail - bolts beneath the door and on the window sill.
  11. Prep the electrics for winder mechanism removal - front: unscrew flat head screws, remove striped green and black wires, re-screw; back: remove back of plug and pull plain black and green wires out of the plug, then remove from plastic retaining clips in the door.
  12. Remove the 2 nuts and 1 bolt (rear) or 1 nut and 2 bolts (front) that hold the winder mechanism to the door. It won't fall, as at least one bolt protrudes through the door (good design there).
  13. Lift the winder mechanism into the door and then manouvere out through the opening in the door. For the back, feed the wires into the door as you move the mechanism out.

That is it - sounds complicated but is actually one of the nicer jobs (in my opinion). If leaving the lot out of the car for a while, re-attach all screws possible so you know what goes where.
 

John S

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That is a fantastic process to have down in detail, hopefully Styra can have a special "workshop' set up on Topklasse where shuch helpful notes are available for everyone!!!
 
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