For 1990-2009 cars

# Window Regulator Makes a Popping/Clicking/Binding Noise When Cycling Up or Down

Subject: | Window Regulator Makes a Popping/Clicking/Binding Noise When Cycling Up or Down (Replace Counter-Balance Spring) --This bulletin has been revised to include 1997 through 2001 model year coupes and new parts information. It supersedes bulletin 99-T-18, which should be discarded.

Models: | 1996-1999 Saturn S-Series and Wagons built before and including VIN XZ351210

| 1997-2001 Saturn S-Series Coupes built before and including VIN 1Z1140

### Condition

Whenever window is cycled from full up to full down or full down to full up position, window regulator may exhibit a popping, clicking, and/or binding noise that is transmitted into passenger compartment.

### Cause

The window regulator counter-balance spring coils stick or bind together. Whit the force from movement of the window regulator is great enough to overcome this sticking/binding condition, the counter-balance spring coils release and cause spring to vibrate. This transmits a noise through the door structure into the passenger compartment.

### Correction

Refer to the procedure in this bulletin for door where noise is heard.

### Procedures

1. Remove door outer panel on door where noise is heard.

• | On 2000 and 2001 models, refer to "Front Door Outer Panel -- Coupe" removal procedure in the Door/Windows/Mirror sections of the 2000/2001 S-Series Body/Electrical (Volume) service manual.

• | On 1996-1999 models, refer to "Front Door Outer Panel -- Sedans and Wagon, " Front Door Outer Panel -- Coupe" or "Rear Door -- Outer Panel" removal procedure in the Doors (BDDR) section of the appropriate model year Body/Repair service manual.

Important: The front and rear door insulator is called the door sound deadener in the 1996 and 1997 Body/Repair service manuals.

2. Remove door insulator assembly.

• | On 2000 and 2001 models, refer to "Front Door Insulator" removal procedure in the Door/Windows/Mirrors section of 20002001 S-Series Body/Electrical (Volume I) service manual.

• | On 1998 and 1999 models, refer to "Door Insulator" removal procedure in the Doors (BDDR) section of the 98-99 Body/Repair service manual.

• | On 1996 and 1997 models, refer to "Door Sound Deadener Panel" removal procedure in the Doors (BDDR) section of the appropriate model year Body/Repair service manual.

3. Remove door trim panel.

• | On 2000 and 2001 models, refer to "Front Door Trim Panel" removal procedure in the Door/Windows/Mirrors section of the 2000/2001 S-Series Body/Electrical (Volume I) service manual.

• | On 1997 -- 1999 models, refer to "Front Door Trim Panel or Rear Door Trim Panel -- Sedan/Wagons" (BDDR) section of the appropriate model year Body/Repair service manual.

4. Carefully remove enough of door water deflector to gain access to the window regulator mounting bolts.
5. Remove window regulator assembly.

• | On 2000 and 2001 models, refer to "Front Door Window Regulator Assembly" removal procedure in the Doors/Windows/Mirrors section of the 2000/2001 S-Series Body/Electrical (Volume I) service manual.

• | On 1998 and 1999 models, refer to "Window Regulator Assy--Front Door" or Rear Door Window Regulator/Motor -- Sedan/Wagon removal procedure in the Doors (BDDR) section of the 98-99 Body/Repair service manual.

• | On 1997 models, refer to "Front Door Window Regulator/Motor" "Rear Door Window Regulator/Motor -- Sedan/Wagon" removal procedure in the Doors (BDDR) section of the 1997 Body/Repair service manual.

• | On 1996 model, refer to "Front Door Window Regulator/Motor -- Sedan/Wagon or "Rear Door Window Regulator/Motor removal procedure in the Doors (BDDR) section of the 96 Body/Repair service manual.

6. Mark sector gear with a grease marker or awl at pinion gear shaft to note location of sector gear on window regulator. The gear will be moved and needs to be returned to this location prior to installation of regulator.
7. For Manual Windows, continue to step 11.
8. For Power Windows, carefully remove wiring harness plastic retainer located just above and forward of window regulator motor.
9. Carefully remove wiring harness plastic retainer closest to power door lock switch (front doors) or power window switch (rear doors).
10. To allow movement of wiring harnesses later on perform the following:

• | On front doors, route window regulator motor end of wiring harness through speaker opening in door to inside of door.

• | On rear doors, route window regulator motor end of wiring harness motor end of harness to outside of door.

Important: When cycling window regulator, make sure window regulator is pointing in a direction away from anything that lift arm(s) and sash bar may contact.

11. Carefully cycle window regulator to full up position.

• | On Manual Windows

• | Install handle onto regulator.

• | Hold regulator backing plate with one hand and crank window regulator to full up position. Do not remove handle at this point.

• | On Power Windows

• | Make sure the ignition is in the RUN position

• | If working on rear door, make sure rear door power window switch is connected to wiring harness.

• | While holding the window regulator motor with one hand, connect wiring harness connector to motor and carefully cycle regulator to full up position and disconnect wiring harness connector.

12. Remove window regulator mounting bolt located closest to counter-balance spring mounting tab wrapped around backing plate. This will allow clearance for spring removal.
13. With window regulator lying on bench, install a C-clamp or C-clamp style locking pliers over regulator spring with flat spot of upper leg located directly over center of spring. Make C-clamp snug enough to stay in place. this will ensure spring does not come off regulator prematurely.
14. Grab counter-balance spring mounting tab end with a pair of locking pliers. Make sure the tension id tight. While holding the regulator with one hand, carefully pry back the spring with locking pliers while raising spring enough to allow tab to clear backing plate side of regulator. Once spring clears regulator backing plate, slowly release tension on spring and allow it to relax.
15. Remove C-clamp or C-clamp style locking pliers installed previously.
16. Before removing spring from window regulator backing plate shaft, note the orientation if spring for correct installation of new spring. Remove spring from regulator backing plate shaft.
17. Install new spring part (P/N 21171344 -- Sedan/Wagon Front, 21171345 -- Sedan/Wagon Rear or 21171493 -- Coupe) onto regulator backing plate shaft in same orientation noted previously.
18. Install C-clamp or C-clamp style locking pliers over regulator spring with flat spot of upper leg located directly over center of spring. Make C-clamp snug enough to stay in place. This will ensure the spring does not come off regulator prematurely.
19. Grab counter-balance spring mountain tab end with locking pliers. Make sure the tension is tight. While holding regulator with one hand, carefully pry back spring with locking pliers while raising spring enough to allow the tab to clear backing plate side, carefully lower spring and gradually relax spring tension to let spring tab rest on backing plate side.
20. Remove C-clamp or C-clamp style locking pliers previously installed.

Important: When cycling window regulator, make sure window regulator id pointing in a direction away from anything that lift arm(s) and sash bar may contact.

21. Carefully cycle window regulator back to position previously marked.

• | On Manual Windows

• | Hold regulator backing plate with one hand and crank window regulator to position previously marked.

• | Remove handle from regulator.

• | On Power Windows

• | Make sure the ignition is in the RUN position

• | If working on rear door, make sure rear door power window switch is connected to wiring harness.

• | While hold the window regulator motor with one hand, connect wiring harness connector to motor and carefully cycle regulator to position previously marked and disconnect wiring harness connector.

22. Install the window regulator mounting bolt located closest to counter-balance spring mounting tab wrapped around backing plate. Only install bolt far enough to remain in backing plate allowing enough clearance for door structure to fit between bolt head and backing plate.
23. For Manual Windows, continue to step 25.
24. For Power Windows, route power window wiring harness back into door and secure wiring harness retainer into door structure. Make sure wiring harness routing is correct so it does not interfere with window regulator movement.
25. Install window regulator assembly.

• | On 2000 and 2001 models, refer to "Front Door Window Regulator Assembly" installation procedure in Doors/Windows/Mirrors section of 2000/2001 S-Series Body/Electrical (Volume I) service manual.

• | On 1998 and 1999 models, refer to "Window Regulator Assy -- Front Door" or "Rear Door Window Regulator/Motor -- Sedan/Wagon" installation procedure in the Doors (BDDR) section of the 98-99 Body/Repair service manual.

• | On 1997 models, refer to "Front Door Window Regulator/Motor" or "Rear Door Window Regulator/Motor -- Sedan/Wagon" installation procedure in the Doors (BDDR) section of the 1997 Body/Repair service manual.

• | On 1996 models, refer to "Front Do Window Regulator/Motor -- Sedan/Wagon" or "Rear Door Window Regulator/Motor" installation procedure in the Doors (BDDR) section of the 96 Body/Repair service manual.

Important: When servicing a newer style regulator that has the nuts attached to the backing plate, installation of the washers and nuts is not necessary.

26. From outside of door structure, install two washers (P/N 15650962) and nut (P/N 11508277) to each window regulator bolt and tighten.

Tighten
Tighten the window regulator fasteners to 22 N·m (16 lb ft).

Important: Replace water deflector if damaged.

27. Carefully install the water deflector. Make sure there are no creases left around the door structure mounting surface. If creases are present, water leaks and/or dust intrusion can result.
28. Install door trim panel.

• | On 2000 and 2001 models, refer to "Front Door Trim Panel" installation procedure in the Door/Windows/Mirrors section of the 2000/2001 S-Series Body/Electrical (Volume I) service manual.

• | On 1997-1999 models, refer to "Front Door Trim Panel" or "Rear Door Trim Panel -- Sedan/Wagon" installation procedure in the Doors (BDDR) section of the appropriate made year Body/Repair service manual.

• | On 1996 models, refer to "Front Door Trim Panel -- Sedan/Wagon" or Rear Door Trim Panel -- Sedan/Wagon " installation procedure in the Doors (BDDR) section of the 96 Body/Repair service manual.

29. Install door insulator assembly.

• | On 2000 and 2001 models, refer to "Front Door Insulator" installation procedure in the Doors/Windows/Mirrors section of the 2000/2001 S-Series Body Repair service manual.

• | On 1998 and 1999 models, refer to "Door Insulator" installation procedure in the Doors (BDDR) section of the 98-99 Body/Repair service manual.

• | On 1996 and 1997 models, refer to "Door Sound Deadener Panel" installation procedure in the Door (BDDR) section of the appropriate model year Body/Repair service manual.

30. Install door outer panel.

• | On 2000 and 2001 models, refer to "Front Door Outer Panel -- Coupe" installation procedure in the Doors/Windows/Mirrors section of the 2000/2001 S-Series Body/Electrical (Volume I) service manual.

• | On 1996-1999 models, refer to "Front Door Outer Panel -- Sedan and Wagon," Front Door Outer Panel -- Coupe" or "Rear Door -- Outer Panel" installation procedure in the Doors (BDDR) section of the appropriate model year Body/Repair service manual.

31. Function window to full up and full down positions to ensure proper operation.

#### Part Requirement

21171344 | Spring - Frt S/D Wdo Reg C/Bal (Sedan/Wagon)
21171345 | Spring - Rr S/D Wdo Reg C/Bal (Sedan/Wagon)
21171493 | Spring - Frt S/D Wdo Reg C/Bal (Coupe)
15650962 | Washer - Metric Flat
11508277 | Nut

### Claim Information

To receive credit for this repair during the warranty coverage period, submit a claim through the Saturn Dealer as follows:

Case Type | Description | Labor Operation code | Time
--- | --- | --- | ---
VW | Replace Right Front Door Window Regulator Counter-Balance Spring | Z4027 | 1.3 hrs.
VW | Replace Left Front Door Window Regulator Counter-Balance Spring | Z4028 | 1.3 hrs.
VW | Replace Right Rear Door Window Regulator Counter-Balance Spring | Z4029 | 1.3 hrs.
VW | Replace Left Rear Door Window Regulator Counter-Balance Spring | Z4030 | 1.3 hrs.
ADD | For Power Windows |  | 0.1