Volvo Coupes/Sedans/Wagons 1970-1989 Repair Guide

Door Glass and Regulator

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REMOVAL & INSTALLATION



1800
  1. Remove the door pad and moisture barrier.
  2.  
  3. In the upper center of the door, remove the two screws holding the upper window stop. Remove the stop from inside the door.
  4.  
  5. Fit the window winder onto the axle and wind the window to the top of its travel, then lower it about a quarter turn. Hold the glass while doing this to keep it in position.
  6.  
  7. Hold the glass with two hands; slide the glass rearwards and lean the top of the glass inward (toward the center of the car). This will unhook the glass from the lifting mechanism.
  8.  
  9. Lower the lift mechanism and lift the glass out of the door.
  10.  
  11. If the lifting mechanism (regulator) is to be replaced, remove the five screws holding it to the door and lift it out of the door.
  12.  
  13. When reinstalling, make sure that the glass is centered and runs easily in the guides. The rear guide (track) is adjustable to get a weathertight seal on the glass.
  14.  
  15. With all mechanical components, including the upper stop installed, test the window through the full range of motion. There should be no binding or resistance and the glass should remain square to the door during its travel.
  16.  
  17. Install the moisture barrier and the door pad.
  18.  

140 and 160 Series

See Figures 1, 2 and 3

  1. Lower the window almost to its bottom position.
  2.  
  3. Remove the door pad and the moisture barrier.
  4.  
  5. Remove the screws which hold the bracket for the front vertical track and remove the bracket. (This step is omitted for rear doors.)
  6.  
  7. Remove the sealing strip which runs around the door frame.
  8.  
  9. Remove the attaching screws which hold the door frame to the door. Screws are located on both the front and rear edges of the door.
  10.  



Click image to see an enlarged view

Fig. Fig. 1: The upper door frame-140 and 164 series

  1. Lift the door frame straight up and out of the door.
  2.  
  3. Remove the guide roller at the upper edge of the door.
  4.  
  5. Support the window within the door and remove the locking springs holding the sliding rails to the lift arms. Don't allow the window to fall or get misplaced within the door.
  6.  
  7. Lift the window off the pins in the winder and remove the glass from the door.
  8.  
  9. If the regulator is to be removed from the car, remove the retaining bolts and remove the mechanism.
  10.  



Click image to see an enlarged view

Fig. Fig. 2: To remove the glass, disconnect it from the window regulator (shown)

  1. When refitting the glass into the carrier, make sure that the correct spacing is maintained. The distance (A) is 3.1 in. (80mm) for front windows and 6.7 in. (170mm) for the rear glass.
  2.  



Click image to see an enlarged view

Fig. Fig. 3: Place the window glass in its lower channel with the correct spacing (see text for dimension "A")-Upper: front glass; Lower: rear glass

  1. Reconnect the glass to the regulator pins and install the locking springs.
  2.  
  3. Install the upper guide roller.
  4.  
  5. Install the door frame and secure the front and rear retaining screws. Make sure that the glass and the frame align properly. Install the sealing strip around the frame.
  6.  
  7. Install the lower track bracket. Run the window through the full up and down travel and check for any signs of binding or resistance. Check also that the glass is even in its match to the door frame and is not under any abnormal tension, particularly in the closed position.
  8.  
  9. Install the moisture barrier and the door pad.
  10.  

200 Series
MANUAL WINDOWS

See Figure 4

  1. Remove the door pad and the moisture barrier.
  2.  
  3. If the glass is to be replaced or removed, remove the safety catches from the pins on the two lower arms and lift out the glass. The regulator can be removed without removing the glass, but the glass must be supported within the door.
  4.  



Click image to see an enlarged view

Fig. Fig. 4: The arrows indicate retaining bolts for the 200 series manual window regulator-make sure the clips are in place before installing the door panel

  1. To remove the regulator (lift mechanism), remove the safety clips from the pins on the two lower arms. Remove the five bolts holding the regulator to the door and remove the regulator.
  2.  
  3. When reassembling, be careful not to scratch or knock the glass while fitting the new regulator into the door. Make certain the safety clips are firmly seated on the pins.
  4.  

POWER WINDOWS

See Figures 5 and 6

  1. Remove the door pad and the moisture barrier.
  2.  
  3. If the glass is to be replaced or removed, remove the safety catches from the pins on the two lower arms and lift out the glass. The regulator can be removed without removing the glass, but the glass must be supported within the door.
  4.  
  5. Disconnect the wiring for the motor. On cars through model year 1979, the wiring must be disconnected at the fusebox. 1980 and later models may be disconnected at the armrest control panel.
  6.  
  7. Remove the five bolts holding the regulator and remove the regulator from the door.
  8.  



Click image to see an enlarged view

Fig. Fig. 5: Remove the retaining bolts for the power window regulator-200 series models

  1. When reinstalling, tighten the mounting screws just enough to hold position and no more. Attach the glass to the regulator with the safety clips and make sure they are properly seated.
  2.  
  3. Hook up the electrical connections and check the operation of the motor. Run the window up and down, checking for evenness of motion and smoothness of operation. The four mounting bolts closest to the front can be loosened to eliminate binding. Loosen the screws and operate the window up and down. As the regulator seeks its best position, tighten the bolts to hold it in place. It should take five seconds for the window to open fully.
  4.  



Click image to see an enlarged view

Fig. Fig. 6: Loosen only the four indicated bolts to adjust for window binding-power window equipped 200 series

  1. Raise the window to its stopped position. Loosen the stop (at the forward edge of the regulator) and raise the window as far as it will go. Readjust the stop to mesh with the gears and tighten it in place.
  2.  
  3. Install the moisture barrier and the door pad.
  4.  

700 Series
MANUAL WINDOWS

See Figure 7

  1. Remove the door pad and the moisture barrier.
  2.  
  3. If the glass is to be replaced or removed, remove the safety catches from the pins on the two lower arms and lift out the glass. It may be necessary to remove the lower channel from the glass. The regulator can be removed without removing the glass, but the glass must be supported within the door.
  4.  

If replacing the glass in a rear door, the front window track must be removed. Loosen the two bolts in the edge of the door and the track will come free.

  1. To remove the regulator (lift mechanism), remove the safety clips from the pins on the two lower arms. Remove the five bolts holding the regulator to the door and remove the regulator.
  2.  



Click image to see an enlarged view

Fig. Fig. 7: Exploded view of the manual window regulator mounting-700 series

  1. When reassembling, be careful not to scratch or knock the glass while fitting the new regulator into the door. Make certain the safety clips are firmly seated on the pins.
  2.  
  3. If installing new glass, a new piece of cushioning tape must be placed in the lower channel.
  4.  
  5. After reinstallation, check the travel of the glass and eliminate and binding or stiffness. Loosen the upper stop bolt (located just forward of the spring for the door release) and wind the window to its full up position. Press the bolt rearwards and retighten it.
  6.  

POWER WINDOWS

See Figure 8


WARNING
The use of the correct special tools or their equivalent is REQUIRED for this procedure.

  1. Remove the door pad and the moisture barrier.
  2.  
  3. If the glass is to be replaced or removed, remove the safety catches from the pins on the two lower arms and lift out the glass. It may be necessary to remove the lower channel from the glass. The regulator can be removed without removing the glass, but the glass must be supported within the door.
  4.  

If replacing the glass in a rear door, the front window track must be removed. Loosen the two bolts in the edge of the door and the track will come free.

  1. Label or diagram the wiring at the motor and disconnect the wiring using Volvo tool 6351 or similar to disconnect the terminals.
  2.  
  3. To remove the regulator (lift mechanism), remove the safety clips from the pins on the two lower arms and the upper arm. Remove the four bolts holding the regulator to the door and remove the regulator.
  4.  



Click image to see an enlarged view

Fig. Fig. 8: Exploded view of the power mirror window regulator mounting-700 series

  1. When reassembling, be careful not to scratch or knock the glass while fitting the new regulator into the door. Make certain the safety clips are firmly seated on the pins.
  2.  
  3. If installing new glass, a new piece of cushioning tape must be placed in the lower channel.
  4.  
  5. Reconnect the wiring to the motor making certain that correct positioning is obtained.
  6.  
  7. After reinstallation, check the travel of the glass and eliminate and binding or stiffness. Loosen the upper stop bolt (located just forward of the spring for the door release) and press it forward. Wind the window to its full up position. Press the bolt rearwards and retighten it.
  8.  

 
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