Coupe Door Glass Removal

[nthomas1]

Here are revised instructions for removing the door glass from a Fulvia Coupe.   I've posted before on this, but have now simplified and tidied up the information as preparation for the series of handbooks that Glyn Williams and I are working on.   It is a topic that caused much head scratching for me and many others, and is the topic that I get most questions about.

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SUMMARISED INSTRUCTIONS

BACKGROUND
Having struggled for a couple of days to get the window glass out on my Series 2 Coupe, I thought that I'd jot down some instructions while the process is fresh in my mind. It's hoped that these will help others with a similar lack of mechanical skill to myself!  The instructions assume that the door card has been removed. There are other forum threads that explain well how to do this.

DEFINITIONS

- Rear Channel. TAV 76A, Line Item 16. This is the vertical metal guide channel that the rear edge of the door window slides in.

- Front Channel. TAV 76A, Line Item 17. This is the vertical metal guide channel that the front edge of the door window slides in. It projects above the top of the door forming the rear edge of the quarter light assembly

- Regulator Mechanism. TAV 77A, Line Item 1. This is the mechanism that contains the spindle for the window winder, the pantograph mechanism that lifts the window, and the mounting plate that affixes to the inside of the inner door skin.

- Lifting Channel. TAV 77A, Line Item 4. This is the channel attached to the lower edge of the window glass. Two rollers in the Regulator Mechanism run in this channel. The Lifting Channel remains connected to the window glass throughout this procedure.

The TAV pictures are shown at the end of this document.

PROCEDURE
1. Remove the two screws that hold the Rear Channel and withdraw it from the door. One screw is on the inside face of the door at the very top near the trailing edge of the door. The other is on the shut face at the trailing end of the door.
2. Remove the two screws that hold the Front Channel to the inner face of the door. Note that the Front Channel extends above the top of the door and forms the trailing edge of the quarter light assembly. Check that the section of the Front Channel within the door cavity is free to be pushed towards the outer skin of the door.
3. Carefully raise the window glass to its top (fully closed) position. Care must now be taken when raising or lowering the window glass as it is no longer located in the Rear Channel.
4.  Remove the three screws in the triangle around the window winder spindle.  These release the complete Regulator Mechanism.

5. Carefully lower the window to its fully open position.

6. Remove the window winder.

7. Remove the bracket (TAV 77A, Line Item 45) from the trailing edge of the Lifting Channel.

8. Push the splined window winder  spindle into the door cavity and tuck it under the edge toward the leading edge of the door.   This may require some pressure as it is a tight fit, and it might seem at first like it can’t be done!

9. Grasp the Regulator Mechanism (accessed through the large rectangular opening at the bottom of the door) and push it a couple of inches towards the leading edge of the door. This will cause the two rollers to detach from the Lifting Channel.  The lead roller will come out of the end of the Lifting Channel, and the other roller will drop through the gap at the bottom of the Lifting Channel - see the picture below. 
    
10. Pull the window glass (with Lifting Channel attached) through the opening in the top of the door.

11. Pull the Regulator Mechanism through the large rectangular hole at the bottom of the door.

REMOVAL OF FRONT QUARTERLIGHT ASSEMBLY

If required, the quarter light assembly can now be removed as follows:

1. Remove the 3 screws that attach the lower edge of the quarter light to the top of the door. These can be accessed through holes in the bottom rubber seal. There is a good chance that they might be seized and will need to be drilled out.

2. The quarter light assembly can now be pivoted back slightly towards the trailing edge of the door and then swivelled 90 degrees and pulled upwards to withdraw it from the door.