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A fix for power window regulator

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Re: [gti-vr6] (@%$&(# Power window regulators Arthur Emerson <emerson@eideti> Tue, 20 Oct 1998 23:35:27 -0400
[gti-vr6] Power window regulator--bought for $200! "C. Mark Skelton" <skelton@dazel> Wed, 21 Oct 1998 11:55:44 -0500
[gti-vr6] Power window regulator rebuild update Arthur Emerson <emerson@eideti> Thu, 29 Oct 1998 21:54:29 -0500



From gti-vr6-owner@dev.tivoli Tue Oct 20 22:48 CDT 1998
From: Arthur Emerson <emerson@eideti>
To: Derek Lane <thelanes@cyberbeach>
Subject: Re: [gti-vr6] (@%$&(# Power window regulators
Date: Tue, 20 Oct 1998 23:35:27 -0400
Cc: Joel Rybacki <kamakaze@bellatlantic>, gti-vr6@dev.tivoli
 
Derek Lane wrote:
>
> Did the newer GTIs not come with auto up and down on the windows? It was standard
> on the '95s.

No A3 came with one-touch UP until 1998.  If you've got it, there's
about 10,000 other people waiting to find out how.

Let me give a brief status update.  On Sunday, I drilled the old
pulley's pin out on the drill press.  Actually, it was more like
pushed it out.  The pin was just a big rivet, which started to
spin as I was drilling.  I just pulled on the drill press lever
harder, and the rivet head folded upwards and it fell through
the hole.  The steel pulley's stove bolt fit snugly in the resulting
hole, and the pulley fit like a glove.  The big problem (that I
still haven't overcome) is getting the cable back onto the pulley.
There isn't enough slack in the cable, even after compressing
both cable jacket springs.  I suspect that maybe the cable is
slack or knotted up in the motor housing, and [unfortunately]
saw signs of fraying near the motor outlet when I pulled the jacket
back.  I'll have to open up the motor mechanism and take a look.
I'm *not* going to buy a new mechanism.  Repeat three times. :-)

On to the electronics aspect.  The regulator is made in Germany
by Brose (not to be confused with stereo maker Bose).  It has
integral electronics of some type.  If you take a look at
the Bentley schematics for the Jetta rear doors, you can pin out
several functions like child safety window locks.  The electronics
in the regulator apparently handle such fine "Detroit" logic errors,
and prevent power window fights shorting out the circuit. (Think
about it.  If the switches just reversed the motor current, the
driver could push up while the passenger pushes down, and the
result is a dead short.) From what I see, there's 5 pins with no
wires running to them on the schematics.  My speculation is that
one of them is the key to one-touch up.  Hopefully, I won't be
buying a new regulator to find out which one it is..... :-)

-Arthur



From gti-vr6-owner@dev.tivoli Wed Oct 21 12:02 CDT 1998
From: "C. Mark Skelton" <skelton@dazel>
To: gti-vr6@dev.tivoli
Subject: [gti-vr6] Power window regulator--bought for $200!
Date: Wed, 21 Oct 1998 11:55:44 -0500
 
Hey Arthur,

Stick with it, son!  I just had my driver's side window
regulator give up the ghost (almost exactly as you
described)...  Found out that one of the green washer/
guider thingies had broken in half...  Tried to find
the whole unit in the aftermarket--no dice since they
don't carry them...

What I ended up doing was shelling out $200 for a Jetta
power window regular/track unit...  It is exactly the
same part as we were able to match up the VW#'s--it's
in the car and working--voila...

However, if you do manage to get the thing back together,
it would be insightful for you to post your results...
I kept my old one (was supposed to give it back to the
junkyard but *SHHHH!*)...  So, if I get a hankerin' to
fix the old one b/c I don't want to buy a new one (which
I'm sure you can understand that I *DO NOT* want to spend
another $200!), I'd like to know what your solution was...

I agree that it is insane how penny-pinching VW is with
some of their parts...  This mechanism is *DESIGNED* to
break...

Mark


- - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
  C. Mark Skelton
  Field Sales Engineer - DAZEL Corporation
  301 Congress Ave, Suite 1100, Austin, TX 78701
  Voice: 512-494-7300	    Pager: 800.SKYPAGE #1156935
  Email: &#115;kelton&#64;dazel<img src=/i/dc.gif border=0 width=35 height=15>  Web: http://www.dazel.com/



From gti-vr6-owner@dev.tivoli Thu Oct 29 21:01 CST 1998
From: Arthur Emerson <emerson@eideti>
To: gti-vr6@dev.tivoli
Subject: [gti-vr6] Power window regulator rebuild update
Date: Thu, 29 Oct 1998 21:54:29 -0500
 
Two weekends ago, I managed to drill the rivit holding the broken
pulley axle out of my broken power window regulator.  The metal
pulley from The Home Depot bolted in perfectly.  As I was trying
to wrestle the cable back over the pulley (impossible job!), I
realized that the motor housing had a cable knot in it.  After
removing the motor assembly, de-fraying a few broken cable strands,
and putting everything back together again, I managed to get the
cable over the pulleys after cutting two coils out of one of
the cable tensioner springs.

LAst Saturday, I did a rush-install of the unit for reasons that
the warranty police need not hear.  :-)  It worked fine for the
first few cycles, and then got jammed going down again.  It sounds
like the cable is frayed and knotting up in the motor housing
again.  I'm thinking about buying a piece of cable from The Home
Depot, and snaking it through the existing cable sleeves.  I have
figured out how to terminate both ends with caps, so that shouldn't
be a problem.  The window does work, but it occasionally gets jammed
going down.  Putting it up and down a few times usually gets it past
the jam, so I can live with it for now.

On the express up feature, I disassembled the controller.  There's
two chips in it, along with a relay and a sprinkling of other
surface-mount support stuff.  I still haven't put the door panel
on tightly yet, and may drive off into the woods to hack at the
unused pins on the controller.  The reason for the woods drive
is that the alarm sounds whenever you plug the window regulator
back in and turn the ignition on for the first time.  I'm not going to
be very popular if I do that several more times in my driveway..... :-)

-Arthur



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