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Old 11-19-2012, 11:11 PM
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bluebee bluebee is offline
Seek to understand,^Value
Location: San Jose, California
 
Join Date: Mar 2008
Posts: 21,283
Mein Auto: 02 BMW 525i M54 auto 130K
Here is a step by step pictorial DIY for how to swap out your old OEM Kuster window regulator for a new $50 "Replacement brand" window regulator starting with the original OEM window regulator in place assuming you've already removed the inside window trim:

With a T25 Torx, loosen the left window clamp bolt:

Then loosen the right window clamp T25 Torx bolt:

Pull the window glass up, rear end first, dipping the front end downward to pull it free from the door:

Now you can get to the 5 bolts and one harness connector that you need to remove:

Remove the top right T25 bolt that was previously behind the glass:

Then remove the top middle T25 bolt that was previously behind the glass:

Remove the top left T25 bolt:

Loosen the 10mm bottom front bolt (you do not need to remove it completely):

Loosen the 10mm bottom rear bolt (you do not need to remove it completely):

Loosen the T25 clip bolt holding the motor bracket to the door (you do not need to remove it completely):

Disconnect the motor harness from the window regulator motor by pressing on the side tabs:

Remove the five T20 screws holding the motor on the old window regulator and transfer those screws and the motor to the new window regulator:

Note that the new window regulator comes with everything EXCEPT the top three T25 bolts and the five T20 motor bolts and the motor itself:

Insert the new window regulator into the door by tilting it to the left, laying it on its left side and then straightening it up to the right:

Insert the top forward T25 bolt from the old window regulator mounting:

Insert the top middle T25 bolt from the old window regulator mounting:

Insert the top rear T25 bolt from the old window regulator mounting:

Make a note of the thick rubber o-ring sandwiched between the motor bracket and the clip holding the motor bracket to the door frame:

Attach the clip to the door frame with the T25 bolt:

Attach the motor wiring harness connector to the motor taking care to route the wires behind the bracket:

Tighten the 10mm bolt at the bottom front:

Tighten the 10mm bolt at the bottom rear:

Now it's time to adjust the window in the clamps so that it raises and lowers straight all the way:

Adjust the rear window clamp so that the window raises and lowers straight and all the way:

Adjust the front window clamp so that the window raises and lowers straight and all the way:

Here is a closeup of the adjustment bolt (notice it's a Phillips head bolt on the new window regulator):

Also notice that the window clamp center bolt is a hex-head bolt on the new window regulator:

Once you have everything adjusted so that the window goes up and down straight and all the way, you actually then REMOVE the center bolt to add Loctite blue:

Then, you tighten the center bolt for the final test before reassembling the door panels:

Once you have the window aligned to the door, you can replace the inside top window trim piece:

If the airbag was connected, disconnect the battery, and remove the airbag three 10mm bolts and harness connector.

Then place the vapor barrier back on the door, taking care to align all holes as needed.

Then reattach the speaker housing using the three Phillips head screws and then reattach all wires and attach the window trim as described previously:
(See photos above as for some reason, I don't have a picture of the speaker box being reattached.)


EDIT: Even after all this, I ended up adjusting the window glass location wrong!
So I opened this thread in the hopes of finding out HOW to properly adjust the window glass before buttoning it all up!
- Do we have a step-by-step DIY for ADJUSTING window glass when replacing the regulator?
http://www.youtube.com/watch?feature...&v=RP-2wQx6Wfs
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Last edited by bluebee; 11-20-2012 at 09:47 AM. Reason: Added detail.
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