(03-01-8112) Improvements for door windows, CV
Symptom: Symptoms experienced by the customer can be one or more of the following:
Rattles and/or creaking noise from door windows and/or side windows and/or their mechanisms
Creaking and/or scraping noises from door window seals and/or side window seals
The door windows cannot be closed and/or the operation is very slow
Wind noises from door windows and/or side windows when driving
Water leaking in from door windows and/or side windows when driving in rain or when washing the car
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TECHNICAL NEWS
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Bulletin Nbr:
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03-01-8112
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Date:
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Mars 2003
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Market:
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all
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Improvements for door windows, CV
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All 900 CV M94-M98 and 9-3 (9400) CV M98-M03
Improved methods for repair and adjustment.
Symptom description
Symptoms experienced by the customer can be one or more of the following:
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Rattles and/or creaking noise from door windows and/or side windows and/or their mechanisms
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Creaking and/or scraping noises from door window seals and/or side window seals
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The door windows cannot be closed and/or the operation is very slow
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Wind noises from door windows and/or side windows when driving
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Water leaking in from door windows and/or side windows when driving in rain or when washing the car
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Note
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The following method is described for one side of the car but it is applicable to both sides.
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1.
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Remove the front door trim as per WIS 8. Body - Interior equipment - Adjustment/Replacement - Door trim, CV.
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2.
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Remove the rear-view mirror WIS 8. Body - Glass, windows and mirrors - Adjustment/Replacement - Rear-view mirror CV.
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3.
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Remove the door window as per WIS 8. Glass, windows and mirrors - Adjustment/Replacement - Door window, CV.
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4.
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Remove the seal from the front support bar.
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5.
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Check that the front support bar is not twisted and that the spot welds are intact.
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Note
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The door window front support bar has been reinforced with extra and larger spot welds from and including Vehicle Identification Number 27006517. For cars after this Vehicle Identification Number it is sufficient to just check the support bar as per the instructions below.
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6.
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Undo the lower mounting adjustment nut.
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7.
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If the support bar is twisted, straighten the support bar so that it is straight the whole way.
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8.
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If one or more of the spot welds are broken, fit a Pop rivet, part no. 82 35 178, in the hole in the support bar and fit a washer, part no. 70 88 073, on the rear side and rivet together. The Pop rivet must fasten the support bar together with the reinforcement. If necessary a hole can also be drilled into the upper section of the support bar and a second Pop rivet plus washer fitted there.
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9.
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Check the front support bar lower mounting.
The lower mounting for the door window front support bar has been moved back (by approx. 3 mm). This was done as a temporary solution by grinding the adjustment hole from and including Vehicle Identification Number 27003542. The final solution involves the plate with the adjustment hole being moved from and including Vehicle Identification Number 27004929. For cars after these Vehicle Identification Numbers, check the support bar as per instructions in step 14 and proceed to step 15.
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10.
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Remove the lower mounting adjustment nut completely and screw in the adjustment screw. Carefully bend the support bar straight forwards.
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11.
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Modify the adjustment screw hole with a round file. The objective is to increase the extent of the adjustment back by 3 mm.
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12.
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Protect the modified area against corrosion.
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13.
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Fit the adjustment screw and adjustment nut and adjust the support bar as far back as possible.
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14.
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Fit the door window and check the support bar tolerances. Measure the distance from the bottom of the support bar to the front edge of the door window when the door window is in its lowest position. Then measure the same distance with the door window in its top position and measure at the upper end of the support bar. The distance must be approx. 5 mm. The measuring must be done without the seal.
If the measured distances are considerably greater than 5 mm, return to step 9.
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15.
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Remove the door window.
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16.
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Check the door window bushes with regard to wear and/or cracks. Replace the bushes for new ones if necessary. The bushes can also be replaced if they caused noise.
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Note
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The bushes in the door window have been replaced twice, the first time to grey, from and including Vehicle Identification Number X7057279 and the second time to black, from and including Vehicle Identification Number 27016225. For cars after Vehicle Identification Number 27016225 check the bushes and replace only if necessary.
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Use only the new black bushes, part no. 53 61 910.
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17.
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Fit the new bush, see also step 18.
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Note
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No lubrication or similar of the bushes is permitted, nor of the rear vertical support bar. Any lubricant must be removed by cleaning the bar and bushes thoroughly.
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18.
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If the door window is slow or presses against the weatherstrip, fit a plastic washer beneath the upper bush on the door window.
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Note
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The door windows have been optimised with a plastic washer beneath the upper bush from and including Vehicle Identification Number 27015384. The plastic washer has not been fitted on all door windows and can also be found on just one side of the car. For cars after this Vehicle Identification Number check the operation and carry out this step only if necessary.
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19.
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Remove the upper bush.
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20.
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Fit a plastic washer beneath the bush.
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21.
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Use 69 36 371 plastic washer.
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23.
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Fit the seal to the front support bar.
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24.
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Fit the door window and the outer seal and check the operation by running the window down and up several times.
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25.
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If there is any noise, check the following points and carry out the diagnostic procedure described.
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26.
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Check the bush in the mechanism lifting arms. Lubricate if necessary.
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27.
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Check the engine and the gear segment in the mechanism. Lubricate if necessary.
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28.
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Check the guide bush in the mechanism's horizontal bar (green or white bush). Clean and lubricate if necessary.
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29.
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Check the clips for the guide bushes in the horizontal bars. Modify the clips as necessary. The clips may move with the bars when the door window is lowered/raised and create creaking and/or scraping noises. Use white vaseline for lubrication, part no. 79 97 851.
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30.
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Fit the front door trim as per WIS 8. Body - Interior equipment - Adjustment/Replacement - Door trim, CV.
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31.
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Carry out adjustment of the door windows and side windows as per TN 03-01-8113.
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