Chapter 1 Routine maintenance and servicing

Bodywork and fittings 11•1531.20 Regulator retaining rivets (A) andlower window glass guide securingscrews (B) on rear doorwindow glass guide securing screws (seeillustration).21 Support the window glass then, havingpushed the regulator into the door cavity,disconnect the regulator arm from it. Removethe regulator assembly.Refitting22 Refitting is a reversal of the removalprocedure, ensuring that the window regulatoris securely riveted to the door. Check theoperation of the window regulator, bytemporarily refitting the regulator handle and,if necessary, adjust the window glass guide toensure that the window glass does not stickor judder.23 Re-secure the PVC sheet then refit thedoor inner trim panel as described in Section21.32 Door window glass -removal and refitting 3Front side door glassRemoval1 Remove the door inner trim panel, asdescribed in Section 21.2 Locally detach the PVC sheet from the doorto allow access into the door cavity. Do nottear the sheet; cut closely around the clips, asrequired.3 Remove the door belt weathersealmoulding as described in Section 10.4 Remove the two screws securing thewindow glass lifting channel to the regulatorassembly, through either their upper or loweraccess holes. Support the glass as the screwsare removed.5 Remove the window glass by tilting itforwards towards the hinge end of the door,then withdraw it towards the latch end.Refitting6 To refit, position the window glass into thedoor by reversing the method of removal.7 Loosely refit the two screws to hold thewindow glass lifting channel to the regulatorassembly, but do not tighten them at thisstage.8 Raise the window glass fully, then tightenthe retaining screws through their upperaccess holes. This ensures correct positioningof the window glass in its aperture.9 Refit the door belt weatherseal moulding asdescribed in Section 10.10 Re-secure the PVC sheet then refit thedoor inner trim panel as described in Section21.Rear side door sliding glassRemoval11 Remove the door window regulator, asdescribed in Section 31, then fully lower thewindow glass into the door.12 Remove the door belt weathersealmouldings in a similar manner to thatdescribed in Section 10.13 Remove the remaining two window glassguide securing screws from their location atthe top of the door, and disengage the topof the guide.14 Manoeuvre the fixed rear quarter windowglass forwards and out from its location, alongwith the window glass guide. Lift out theplastic strip.15 Manoeuvre the door window glass up andout of the door, from the exterior side of thedoor.Refitting16 Refitting is a reversal of the removalprocedure, ensuring that the fixed rear quarterwindow seats correctly in its location, and thatthe window glass guide holds the windowglass correctly (refer to Section 31).Rear side door fixed quarterglass17 The fixed rear quarter window glass isremoved and refitted in conjunction with therear side door sliding glass describedpreviously in this Section.Rear door glass (Couriermodels)18 The rear door window glass on Couriermodels is removed and refitted using thesame technique as for the fixed side windowglass described in Section 33.33 Side window glass -removal and refitting3Fixed side window glassRemoval1 The lip of the weatherseal surrounding thewindow glass must be released from the topand sides of the body aperture flange, using asuitable tool, before exerting pressure fromthe inside of the vehicle to remove the glass.Any surrounding interior trim should beremoved. It is important that an assistanthelps and holds the glass from the outside asit is pressed out from the inside.2 With the assembly removed from thevehicle, detach the weatherseal from thewindow glass.3 If the weatherseal is to be re-used it shouldbe cleaned. Do not use petrol, white spirit orother similar substances, as they may causerapid rubber deterioration. Ensure that theglass groove in the weatherseal is free fromany sealant or glass fragments.4 Ensure that the body aperture flange is freefrom any sealant also.Refitting5 Commence refitting by attaching theweatherseal to the window glass, ensuringthat it is seated correctly.6 Insert a length of nylon or terylene cord intothe body aperture flange groove of theweatherseal, so that the cord ends emerge atthe top centre of the window, and overlap byapproximately 150.0 mm.7 Offer the assembly to the body aperture,and engage the lower lips of the weathersealover the body aperture flange. Ensure that theengagement of the weatherseal lips is nothampered in any way, and that the cord endsare protruding inside the vehicle.8 With an assistant applying a gentle evenpressure on the window glass from theoutside, pull one end of the cord at rightanglesto the glass. This will pull the inner lipof the weatherseal over the body apertureflange.9 When the cord has been pulled halfwayaround the aperture, repeat the procedurewith the other end of the cord. The cordshould release when the window glass is fullyfitted.10 Refit any disturbed interior trim asnecessary.Hinged side window glassRemoval11 With an assistant standing outside readyto take the window, unscrew the single screwsecuring each hinge, then open the windowand unscrew the two screws securing thecatch to the body. Withdraw the window.12 The weatherstrip can now be removedand refitted, if required.Refitting13 To refit the window, have your assistantstand outside and offer up the window so thatboth hinge leaves enter their sockets, thenloosely refit the catch securing screws. Refitthe hinge securing screws, then adjust thecatch position to ensure that the window isclamped evenly on to the weatherstrip overthe whole mating surface when the catch isfastened. Tighten all screws securely.Sliding side window and glassRemoval14 To remove the complete sliding windowassembly on Courier Kombi models requiresspecial cutting equipment and supplies of111595Ford Fiesta Remake