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AudiDoc
AudiDoc, Independent Audi Shop Owner
Category: Audi
Satisfied Customers: 6456
Experience:  I've been working on Audis since I was 18 and own an independent Audi repair and performance shop
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Hi, Thanks very much for helping. I have ordered a new drivers window regulator

This answer was rated:

Hi,
Thanks very much for helping.
I have ordered a new driver's window regulator for my 2002 Audi Allroad and plan to install it myself. I'm reasonably confident I can figure things out, but I thought I'd ask if you have any tips or warnings associated with this particular job.

AudiDoc :

Hello, I'm Jason. I will do my best to answer your question quickly and accurately using the information you have provided.

AudiDoc :

First thing I'm curious about is why the complete regulator was ordered

AudiDoc :

typically, it's only the plastic guide/clamps that break, and need to be replaced

AudiDoc :

unless one of the cables frayed or became unwound

Customer:

Because the Audi shop was going to charge me $600. they said it's all one unit.

AudiDoc :

they're looking to make money. I can't remember the last time I've had to replace a complete front regulator on a C5 Audi

Customer:

Yeah, I suspect so. They often give me that impression.

AudiDoc :

Usually, front window problems (slow to move/binding) are repaired by about 12 bucks worth of clips/guides

Customer:

They said one of the cables was worn down to a few strands.

AudiDoc :

they removed a door panel to verify this?

AudiDoc :

here's why I ask. To change a regulator is a bit more involved than changing guides

AudiDoc :

and requires drilling and a rivet gun

Customer:

yes. In fact, without my permission, they took it upon themselves to cut this cable so that they could close the window.

AudiDoc :

and this is why independent shops like mine thrive

AudiDoc :

however, it is what it is. I can help you through this

Customer:

OK, well, consider me a future customer. I'm sick of these guys.

AudiDoc :

:-) Good

AudiDoc :

I'll leave you my direct link for future reference, once we go through this

AudiDoc :

Also, not only do I own an independent Audi shop, I also own a 2002 Allroad

Customer:

Please tell me you're in Vancouver.

AudiDoc :

only about 3k miles away

Customer:

Would you like to do it for me?

AudiDoc :

it's actually not horrible, if you're reasonably mechanically competent

Customer:

Sorry, 3k. I thought you meant 3 km.

Customer:

I'm quite handy. Used to maintain my Austin Mini Cooper when I was younger.

AudiDoc :

ok, let's start with the door panel...

AudiDoc :

and this is all from memory, so bear with me

Customer:

I see two screws at the top, front and back.

AudiDoc :

there are two small phillips screws at the top of the .....

AudiDoc :

ok, good

AudiDoc :

got that

AudiDoc :

you need to remove the window switch panel

AudiDoc :

look under it towards the front. There is a small hole at the bottom of the door pull

Customer:

by the way, can i save this conversation when we're done?

AudiDoc :

you need to stick a small screwdriver in there to release the window switch assembly....

AudiDoc :

and yes. You will have a link in your email

Customer:

OK, great. Go ahead.

AudiDoc :

ok, so release the switch panel. Hard to describe, but it levers up from the leading edge

AudiDoc :

you're pushing the release towards the rear to pop it up

Customer:

OK, and that exposes more screws?

AudiDoc :

so, you've got the switch panel up, there is one connector, with an obvious release mechanism

AudiDoc :

no more screws.

AudiDoc :

The whole panel is fixed in place by those two small phillips screws

Customer:

OK

AudiDoc :

then pull the panel straight upward

AudiDoc :

and it will release

Customer:

Sounds good

AudiDoc :

there are 4 more electrical connectors affixed to a little connector station near the inside of the door pull

AudiDoc :

Release all of these. Don't worry about marking them. They're all different

AudiDoc :

now the panel is off

AudiDoc :

now, it gets a bit tricky

Customer:

OK, I'm listening

AudiDoc :

you will then need to remove the entire window/door frame along with the exterior mirror as an assembly

AudiDoc :

it's held on by 4 T45 (I think) Torx bolts

AudiDoc :

mark positions of these using a sharpie

AudiDoc :

they're adjustable

AudiDoc :

you'll see some aluminum wedges that adjust the door carrier position also. Mark these too

Customer:

This is good.

AudiDoc :

ok....now with that....don't unbolt them completely

AudiDoc :

because you need to remove the door wiring harness connectors from the window motor and door latch.....and mirror

AudiDoc :

and release the looms that hold this harness to the window carrier frame....

Customer:

I understand.

AudiDoc :

Oh, wait....one more thing, when the door panel gets released....

AudiDoc :

there is a cable from the door latch to the inner door handle. That's just a hook that you need to remove

Customer:

Got it.

AudiDoc :

DON'T FORGET TO RE-HOOK this when replacing the panel

Customer:

Thanks for that

AudiDoc :

Ok, so, all electrical connectors, off, and wiring harness dangling. Remove T45's

AudiDoc :

Remove entire component carrier with outside mirror. All that's left connected to the car is the outer door skin

AudiDoc :

you will be left with a naked door

AudiDoc :

then remove motor from regulator, unscrew the T30 torx screws holding the window to the regulator clips

AudiDoc :

Then drill out rivets holding regulator to window carrier

Customer:

Can you remember what size those rivets are?

AudiDoc :

sorry.....I actually don't. I just have a good assortment of them handy

AudiDoc :

maybe 3mm?

AudiDoc :

no, not 3

Customer:

good thought ... can just get a kit of different sizes

AudiDoc :

that's too big

Customer:

Are they just regular pop rivets?

AudiDoc :

yep

Customer:

Great. Go ahead.

AudiDoc :

Ok, then time to reinstall

AudiDoc :

and at this point, it's all in reverse....

AudiDoc :

now, with all of this said, I think there is a video

Customer:

Fantastic.

Customer:

Any precautions re car alarm/electrics? Can I just go ahead and do the job with the ignition turned off and the door open?

AudiDoc :

this guy is a bit goofy, but the video will illustrate a lot of what I said

AudiDoc :

no worries about electronics

Customer:

That is awesome.

AudiDoc :

The whole Justanswer thing?

AudiDoc :

yeah, I love the process here

Customer:

Audidoc: I was thinking of selling my Audi because the maintenance costs are so high, but you've opened my eyes to a different possibility. Is there anyone in Vancouver like you that you know of?

AudiDoc :

Washington or BC?

Customer:

B.C.

AudiDoc :

actually, I don't personally know of folks in either area, unfortunately

Customer:

How much longer are you planning to keep yours?

AudiDoc :

and trust me, I understand the cost of dealing with a 10+ year old allroad. Mine? This is my forever car.

AudiDoc :

Very heavily modified, 6-spd, 3rd seat, 450hp car. I'll never get rid of it

AudiDoc :

and mine has 190,000 miles on it

Customer:

I've been warned there are metal filings in my turbochargers. They said that would be a $6,000 job because the engine has to come out. I'm a bit scared of that.

AudiDoc :

how many miles on yours? And the phrase "metal filings in your turbos" is ridiculous

Customer:

72,000 miles

AudiDoc :

if there were, they would fail instantly

AudiDoc :

I replaced mine at 140k miles, only to upgrade to larger ones

Customer:

Wow. my car was previously owned by a German engineer. He said it was fuel-mapped and has 350 horses, and it feels like it.

AudiDoc :

gotcha. It was chipped (software flashed)

AudiDoc :

most likely closer to 315hp

Customer:

yeah. that sounds right. you turn it on and off with the cruise control switch

AudiDoc :

APR chip

Customer:

I love the car but it gets oil leaks all the time and they just can't keep 'em plugged.

AudiDoc :

valve cover gaskets, chain tensioner gaskets and rear cam plugs

AudiDoc :

those are typical

Customer:

Yes. exactly. also the rear propeller shaft seal.

AudiDoc :

automatic? Also common

Customer:

Yes. automatic.

AudiDoc :

Ok, let me give you my link

AudiDoc :

and if you have any other issues come up, please let me know

Customer:

That's fantastic. This has been a great experience. I had no idea this was possible.

AudiDoc :

also, one other quick request. If you get a survey from the site, please take a few moments to fill it out?

AudiDoc :

And very glad to help

AudiDoc :

I'm truly an enthusiast at heart

AudiDoc :

this is more than just a business to me

Customer:

You'll get top marks from me, buddy. Especially if the window job goes well.

AudiDoc :

sounds great. Good luck with it all!

Customer:

Thanks. Take care.

AudiDoc :

likewise

AudiDoc and other Audi Specialists are ready to help you