8.3. Repair of fittings of a body

Possible malfunctions of fittings of doors, their reasons and ways of elimination

Replacement of a cable of a window regulator

Fig. 8.5. Installation of a window regulator and lowering glass of a forward door: 1 – window regulator handle; 2 – cap; 3 – lead; 4 – handle latch; 5 – handle socket; 6 – a bolt with a washer of fastening of a window regulator; 7 – doorway sealant; 8 – the sealant is subwindow internal; 9 – lowering glass; 10 – the sealant is subwindow external; 11 – a bolt with a washer of fastening of lowering glass; 12 – the screw with a nut lamellar; 13 – the screw with a washer of fastening of a frame of glass; 14 – window regulator; 15 – glass sealant; 16 – holder of a sealant of glass; 17 – plugs


1. Remove a cap of 2 (fig. 8.5) of the handle of a window regulator.
2. Remove a latch 4.
3. Remove the window regulator handle assembled and the handle socket 5.

Fig. 8.12. Installation of locks and handles of a forward door: 1 – drive of the internal handle; 2 – facing of the handle; 3 – internal handle; 4 – draft; 5 – holder of draft of the internal handle; 6 – bolt; 7 – washer; 8 – bolt; 9 – washer; 10 – button of the external handle; 11 – screw of fastening of the lock; 12 – washer; 13 – lock switch; 14 – laying; 15 – the spring is lamellar; 16 – lock drive; 17 – button pusher; 18 – door lock spring; 19 – switching off lever spring; 20 – draft of switching off; 21 – the washer is basic; 22 – lock finger; 23 – plate; 24 – door lock; 25 – the handle is external


4. Unscrew the screw of fastening and remove facing 2 (see fig. 8.12) the internal handle of a door.

Fig. 8.26. Installation of an upholstery of a forward door: 1 – the slip is decorative; 2 – pocket; 3 – door upholstery; 4 – armrest; 5 – screw of fastening of a pocket; 6 – nut; 7 – the sticker is internal; 8 – the nut is square; 9, 15 – screws; 10 – holder; 11, 14 – percussion caps; 12 – screw of fastening of a slip; 13 – the slip is angular


5. Unscrew two screws 9 (see fig. 8.26) and remove an armrest 4.
6. Remove a door upholstery (see. "Removal and installation of an upholstery of doors").

Fig. 8.6. Window regulators of doors: 1 – window regulator guide; 2 – guide roller; 3 – coupling; 4 – tip; 5 – the cover is lower; 6 – emphasis; 7 – cup; 8 – rivet; 9 – case; 10 – the cover is top; 11 – brake spring; 12 – gear wheel; 13 – window regulator roller; 14 – drum; 15 – washer; 16 – axis; 17 – carriage; 18 – cable


Fig. 8.9. Installation of a window regulator of lowering glass of a back door: 1 – window regulator; 2 – window regulator handle; 3 – the sealant is subwindow internal; 4 – lowering glass; 5 – the sealant is subwindow external; 6 – emphasis of lowering glass; 7 – bolt; 8 – washer; 9 – a bolt with a washer of fastening of lowering glass; 10 – glass sealant; 11 – the screw with a washer of fastening of a guide of glass


7. Disconnect lowering glass 9 (see fig. 8.5) a lobby or 4 (see fig. 8.9) a back door from the carriage 17 (fig. 8.6) of a window regulator for what turn out, holding glass, two bolts 11 (see fig. 8.5) with washers.
8. Lift glass up and record it, having inserted a wooden wedge between glass and the panel of a door.
9. Turn out five bolts on a forward or back door which the window regulator mechanism (in three points) and a window regulator guide (in two points) fasten to the internal panel of a door.
10. Take out a window regulator through an assembly opening in the door panel.
11. Rotation of a carving tip 4 (see fig. 8.6) as much as possible weaken a tension of a cable 18.
12. Remove the carriage 17 from a guide of 1 window regulator for what raise the carriage, having overcome effort of the thin springing elements of plastic rams.
13. Cut off a cable aflush with external surfaces of the acting cylindrical middle part of the carriage between which internal surfaces there are pressed-out plugs 17 (see fig. 8.5) with a cable fixing a cable on the carriage. Take out the cable rest with plugs.
14. Pass the released ends of a cable through rollers 2 (see fig. 8.6), exempting a guide from a cable. Passing a cable through an emphasis 6 and covers 10, extend on yourself the pressed-out plugs with a cable from grooves of a drum and remove a cable from a drum.

Fig. 8.7. Cable of a window regulator of a forward and back door: 1 – cable; 2 – the plug (in brackets the sizes for a back door are given)


15. Prepare pieces of a steel cable with a diameter of 1,9 mm, length (1645±3) mm for a forward door and (1665±3) mm – for back (fig. 8.7) and four plugs for sinking of a cable. Plugs can be manufactured of a steel tube with an outer diameter of 5 mm, with thickness of a wall of 1,4 mm, 3,3 mm long. Press out plugs on a cable according to the sizes specified fig. 8.7. The ends of a cable slightly to an opayayta tin solder to protect them from an unbraiding (stratifying) and to facilitate drawing of the ends of a cable in an opening on a drum.
16. Insert a cable into the acting cylindrical parts of the carriage so that the pressed-out plugs 17 were in an interval between these parts (see fig. 8.5).
17. Carefully install the carriage with a cable on a window regulator guide, having overcome effort of the springing element of the plastic ram.
18. Pass the ends of a cable on streams of rollers in openings of flanges, an emphasis, covers (poses. 3, 4, 5, 6, 10 in fig. 8.6).
19. Remove one of the ends of a cable through an opening in a drum groove, the next to an end face, free from teeths, and press out the plug so that the distance from the end of the plug until the end of a cable was no more than 3,5 mm. Sinking has to provide effort of a vyryvaniye not less than 1000 N (100 kgfs).
20. Insert the end of a cable with the pressed-out plug into the corresponding groove on a drum (section A-and in fig. 8.6).
21. Pass the second end of a cable through the second opening of the corresponding groove of a drum, the next to a gear wreath. Previously combine a drum groove with an opening of the case to which the drum is attached by an axis. It is similar to the first, press out the second end of a cable.
22. Involve a cable in a groove so that the plug was fixed, and reel up a cable on drum streams. Pay attention to correctness of winding of a cable. The cable has to lay down in streams exactly, without overlapping. Reel up from each party a cable approximately on two turns of a drum that will correspond to average position of the carriage on a window regulator guide.
23. Put on the roller 13 (see fig. 8.6) a window regulator the handle 1 (see fig. 8.5), make by it several turns in both parties and check a cable tension. The tension is checked by the size of its deflection which has to be 10–15 mm from the effort of 50 N (5 kgfs) made at distance of 250 mm from the end of a guide 1 (see fig. 8.6). The effort needs to be put up from a guide profile bottom. Position of the carriage 17 has to correspond to position of the handle which is taken away half way from the top situation. If necessary adjust a tension a carving tip 4. Correctly collected window regulator has to work without noticeable noise, smoothly and without breakthroughs at rise and lowering of the carriage.
24. Fix a window regulator in three points and directing in two points bolts with washers (see fig. 8.5) to the internal panel of a door. Attach lowering glass to the guide carriage two bolts 11 with washers. Establish all earlier removed details and knots.

Restoration of connection of plugs with a cable
1000 N (100 kgfs) of the plug who are pressed out with necessary effort on a cable provide movement of glass at rotation of the handle of a window regulator.
1. If plugs 17 (see fig. 8.5) slip on a cable, remove the carriage 17 (see fig. 8.6) from a guide of 1 window regulator (see. "Replacement of a cable of a window regulator").
2. Accurately press out plugs by effort of 1000 N (100 kgfs).
3. Put carefully the carriage with a cable on a window regulator guide, having overcome effort of the springing elements of plastic rams.
4. Pull a cable a carving tip 4.
5. Check correctness of moving of the carriage to both parties at rotation of the handle and lack of slipping of a cable.
6. Put a window regulator and all removed details and knots on a door.

Replacement of rams of the carriage of a window regulator
1. Remove the carriage 17 (see fig. 8.6) from a guide of 1 window regulator (see. "Replacement of a cable of a window regulator").

Fig. 8.8. Window regulator carriage rams: 1 – carriage; 2 – pin; 3 – ram


2. Beat out pins of 2 (fig. 8.8).
3. Remove rams 3.
4. Install new rams and insert pins 2.
5. Put carefully the carriage with a cable on a window regulator guide, having overcome effort of the springing elements of plastic rams.
6. Pull a cable a carving tip 4 (see fig. 8.6).
7. Check work of a window regulator, having put on the roller 13 the handle 1 (see fig. 8.5) and having turned it a drum on several turns in both parties. Make sure that the ram moves on a guide without noise. Grease if necessary a guide flange.
8. Put into place the repaired window regulator.

Replacement of a spring of a brake of a window regulator
1. Remove a window regulator from a door (see. "Replacement of a cable of a window regulator").
2. Cut off three rivets 8 (see fig. 8.6) fastenings of a cup of the 7th brake to the case 9 of a window regulator and remove a cup together with the roller 13 and a gear wheel 12.
3. Take out the roller 13 from a cup and remove a gear wheel 12. Remove the broken spring of the 11th brake from the roller.
4. Install a new spring of a brake on the roller, watching that its rounds were not gushed over, and short moustaches were in dredging of a head of the roller.
5. Insert the roller assembled with a spring into a brake cup. For simplification of this operation the roller needs to be inserted, at the same time turning it after the first round of a spring concerns a cup.
6. Insert a gear wheel into a cup so that the ledge of a gear wheel got to an interval between spring short moustaches.
7. Install a cup with subcollected details in a window regulator, check that teeths of a gear wheel entered gearing with drum teeths, and a priklepayta a cup to the window regulator case. If there are no rivets of the necessary sizes, it is possible to make them of prutkovy low-carbonaceous steel. Diameter of a core (4±0,15) mm, length of a core is 8 mm, height of a head is 2,4 mm, diameter of a head is 7,1 mm.
8. Establish a window regulator on a door.
9. Check operation of the brake mechanism of a window regulator: if to make the effort of 500 N (50 kgfs) directed down for lowering glass glass should not fall.

Replacement of details of the limiter of doors
1. Remove an upholstery of a door and details established on it.

Fig. 8.2. Fragments of sections of a body: 1 – door limiter; 2 – limiter axis; 3 – motionless link of a loop of a door; 4 – mobile link of a loop of a door; 5 – a bolt of fastening of a loop to a body; 6 – a bolt of fastening of a loop to a door; 7 – bolt; 8 – washer; 9 – the nut is lamellar; 10 – protection cover; 11 – screw of fastening of the protection cover; 12 – cowl; 13 – mobile loop of a cowl; 14 – a bolt of fastening of a loop to a cowl; 15 – a bolt of fastening of a loop of a cowl to a body; 16 – the washer is spring; 17 – cowl emphasis; 18 – cowl emphasis spring; 19 – forward wing


2. Beat out axis 2 (see fig. 8.2) the limiter 1. Be careful: without limiter the door can hit against a body and damage it.
3. Move apart short moustaches of a clamp and take out from connection with the case.
4. Replace the broken details, then collect the limiter.
5. By means of the hammer establish axis 2, previously having combined a limiter opening under an axis on a door with an opening of a welded loop of the limiter on a body.
6. Establish an upholstery and other details.

Replacement of glasses of doors
Glass 9 replacement (see fig. 8.5) a lobby and 4 (fig. 8.9) of a back door are carried out similarly.
1. Remove a door upholstery (see. "Upholstery of doors").
2. Lower glass.
3. Remove internal 8 (see fig. 8.5) and external the 10th subwindow a sealant, by means of the screw-driver exempting them from hooks on internal and external panels.
4. Unscrew screws 13 on a lobby or 11 (see fig. 8.9) on a back door that glass could come out guides. On a back door, holding glass, turn off a bolt 7 and remove an emphasis 6.
5. Establish glasses in such situation to provide access to bolts 11 (see fig. 8.5) on a forward door or 9 (see fig. 8.9) on a back door. Holding glass, turn off bolts of fastening of glass to a window regulator.
6. Take out glass assembled through a subwindow gap.

Fig. 8.11. Lowering glass of a back door: 1 – holder; 2 – laying; 3 – glass


7. If new glass without holder, rearrange on it a holder from old glass. For this purpose remove a holder of 1 (fig. 8.10 and 8.11), having slightly parted its edges. Then correct a holder: groove width in a holder under glass has to be at the top of 7,5 mm, below – 8,5 mm. Press in a holder new glass with laying 2 of the crude rubber moistened with gasoline. At the same time sustain the sizes shown in fig. 8.10 and 8.11. The press fitting can be carried out on the press with manual giving or by means of the hammer. In the latter case rest glass the top part against a wooden support, previously having enclosed soft laying. On an edge of glass put rubber laying 2 and I will embrace, after that blows of the hammer through a wooden bar press glass against the stop. Then cut off laying flush with edges of a holder. Correctly pressed glass should not move forward from a holder by effort of hands.
8. Insert new glass assembled with a holder in a door through a subwindow gap.
9. "Acquire" bolts of fastening of glass to a window regulator and screws of fastening of the directing glasses.
10. At the lowered glass establish subwindow a sealant, having recorded them hooks on door panels by means of the screw-driver.
11. Expose glass on a frame, tighten bolts of fastening of glass to a window regulator and screws of fastening of the doors directing to internal panels. On a back door establish an emphasis 6 (see fig. 8.9) flew down and fix it by a bolt 7 with a washer 8.
12. Establish an upholstery.