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Power Windows: Removal & Installation Mercury Villager I

Windows 31 illustrations ~1860 words

REMOVAL & INSTALLATION

WARNINGVehicles are equipped with air bag supplemental restraint system. Before attempting ANY repairs involving steering column, instrument panel or related components, see SERVICE PRECAUTIONS and DISABLING & ACTIVATING AIR BAG SYSTEM in appropriate AIR BAG RESTRAINT SYSTEMS article.
CAUTIONWhen battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION before disconnecting battery.
  1. Remove the left outer kick panel.
  2. Slide the RH circuit breaker off of the bracket.
  3. Squeeze the tab and pull on the right circuit breaker electrical connector to disconnect it from the circuit breaker. (Scheme 5)
  4. To install, reverse the removal procedure.

Scheme 5

Scheme 5
Scheme 5

Removal

  1. Remove the instrument cluster. See INSTRUMENT PANELS, ANALOG -- VILLAGER or INSTRUMENT PANELS ELECTRONIC -- VILLAGER article.
  2. Remove the center diode strip by carefully prying it from the diode junction box. (Scheme 6)and (Scheme 7).

Scheme 6

Scheme 6
Scheme 6

Scheme 7

Scheme 7
Scheme 7

Installation

  1. Install a new diode strip.
  2. Install the instrument cluster. See INSTRUMENT PANELS, ANALOG -- VILLAGER or INSTRUMENT PANELS ELECTRONIC -- VILLAGER article.
  1. Remove the front door trim panel. See appropriate POWER DOOR LOCKS article.
  2. Remove the two door panel bracket bolts and the door panel bracket. (Scheme 8)
  3. Remove the plastic weather shield from the door.
  4. Lower the window to access the door glass regulator-to-bottom channel bolts. (Scheme 9)
  5. Remove the two door glass regulator-to-bottom channel bolts.
  6. Remove the glass from the door. (Scheme 10)

Scheme 8

Scheme 8
Scheme 8

Scheme 9

Scheme 9
Scheme 9

Scheme 10

Scheme 10
Scheme 10
  1. Position the glass into the door.
  2. Install the two door glass regulator-to-bottom channel bolts. Tighten the door glass regulator-to-bottom channel bolts securely.
  3. Install the plastic weather shield on the door.
  4. Install the door panel bracket and two door panel bracket bolts. Tighten the door panel bracket bolts securely.
  5. Adjust the front door glass. See «FRONT DOOR GLASS»(ref-138783-S24720840982002042900000) under ADJUSTMENTS.
  6. Install the front door trim panel. See appropriate POWER DOOR LOCKS article.

Removal & Installation (Front Doors)

  1. Disconnect the battery ground cable if equipped with power locks or power windows.
  2. Carefully pry off the front door inside handle escutcheon as follows: Insert a standard 1/4 inch screwdriver between the top rear portion of the front door inside handle escutcheon and the front door trim panel. (Scheme 11) Insert a small 1/8 inch screwdriver between the front door inside handle escutcheon and the top of the inside door handle. Insert the screwdriver approximately 15mm (0.6 inch). (Scheme 12) Simultaneously rotate the small screwdriver handle down and, with the larger screwdriver, apply outward pressure against the front door inside handle escutcheon to disengage the upper rear tab. Remove the small screwdriver from the upper area of the inside door handle. Slide the larger screwdriver along the rear portion of the front door inside handle escutcheon to apply outward pressure on the lower rear tab. Insert the small 1/8 inch screwdriver between the front door inside handle escutcheon and the bottom of the inside door handle. Insert the screwdriver approximately 15mm (0.6 inch). Simultaneously rotate the small screwdriver handle up and, with the larger screwdriver, apply outward pressure against the front door inside handle escutcheon to disengage the lower rear tab. Remove the screwdrivers. Grab the rear of the front door inside handle escutcheon and gently pull it away from the front door trim panel. Rock the front door inside handle escutcheon up and down while pulling to disengage the front tabs and remove the front door inside handle escutcheon. Inspect the front door inside handle escutcheon for broken tabs and heavily damaged plastic. Broken tabs are unacceptable. Slightly deformed front tabs are acceptable when only slight straightening is required. Bend the tabs inward to correct for engagement stress.
  3. If equipped with manual windows, slip a clean shop rag between the window regulator handle and the front door trim panel.
  4. Pull the shop rag back and forth to release the window regulator handle clip. (Scheme 13)
  5. Remove the two cover caps and front door trim panel screws.
  6. Remove the two front door trim panel capped screws.
  7. Slide a flat-bladed tool behind each of the retainers and twist the tool to disengage the front door trim panel from the front door.
  8. Disconnect the door lock switch and window regulator control switch electrical connectors, if equipped.
  9. Remove the front door trim panel.
  10. To install, reverse removal procedure.

Scheme 11

Scheme 11
Scheme 11

Scheme 12

Scheme 12
Scheme 12

Scheme 13

Scheme 13
Scheme 13

Removal & Installation (Body Side Door)

Gently pry loose the body side door latch handle bezel and remove it. Slide a suitable tool behind each of the retainers and twist the tool to disengage the body side door trim panel from the body side door. (Scheme 14) To install, reverse removal procedure.

Scheme 14

Scheme 14: Removal & Installation (Body Side Door)
Scheme 14: Removal & Installation (Body Side Door)

Removal (Front Doors)

  1. Remove the front door glass. See «DOOR GLASS»(ref-138783-S01761177712002043000000).
  2. Disconnect the negative battery cable.
  3. Remove the two door brace bolts and the door brace. (Scheme 15)
  4. Disconnect the front power window motor assembly electrical connector.
  5. Remove the four door glass regulator track bolts. (Scheme 16)
  6. Remove the three front power window motor assembly bolts.
  7. Remove the door glass regulator track and the front power window motor assembly as an assembly through the opening in the door.

Scheme 15

Scheme 15
Scheme 15

Scheme 16

Scheme 16
Scheme 16
  1. Install the door glass regulator track and the front power window motor assembly as an assembly through the opening in the door.
  2. Install the three front power window motor assembly bolts. Tighten the front power window motor assembly bolts securely.
  3. Install the four door glass regulator track bolts. Tighten the door glass regulator track bolts securely.
  4. Connect the front power window motor assembly electrical connectors.
  5. Install the door brace and the two brace bolts. Tighten the door brace bolts securely.
  6. Install the glass into the door.
  7. Install the two door glass regulator-to-bottom channel bolts. Tighten the door glass regulator-to-bottom channel bolts securely.
  8. Install the plastic weather shield on the door.
  9. Install the door panel bracket and two door panel bracket bolts. Tighten the door panel bracket bolts securely.
  10. Adjust the front door glass. See «FRONT DOOR GLASS»(ref-138783-S24720840982002042900000) under ADJUSTMENTS.
  11. Install the front door trim panel. See appropriate POWER DOOR LOCKS article.
  12. Connect the negative battery cable.

Removal (Rear Quarter Window)

Both optional power rear quarter glass are activated by an electric actuator, motor and cable system. The actuator, motor, cable and regulator are serviceable as a complete assembly. see scheme 3

  1. Disconnect the negative battery cable.
  2. Remove the rear quarter trim panel. See «REAR QUARTER TRIM»(ref-138783-S26712161962002042900000).
  3. Remove the rear quarter glass trim.
  4. Disconnect the power rear quarter glass motor electrical connector. (Scheme 17)
  5. Pull out the retainer securing the rear quarter power glass latch to glass.
  6. Remove the power rear quarter glass latch.
  7. Remove the two power rear quarter glass latch regulator bolts and the power rear quarter glass latch regulator from the D-pillar. (Scheme 18)
  8. Remove the three power rear quarter glass actuator-to-motor screws and remove the power rear quarter glass actuator and motor from its bracket. (Scheme 19)
  9. Remove the power rear quarter glass actuator, motor, cables and regulator assembly from the vehicle.

Scheme 17

Scheme 17
Scheme 17

Scheme 18

Scheme 18
Scheme 18

Scheme 19

Scheme 19
Scheme 19

Installation (Rear Quarter Window)

  1. Position the rear quarter power glass actuator, motor, cable and regulator assembly in the vehicle.
  2. Install the three power rear quarter glass actuator-to-motor screws.
  3. Install the two power rear quarter glass latch regulator bolts. Tighten the power rear quarter glass latch regulator bolts to 2.8-3.3 INCH Lbs. (3.8-4.5 N. m).
  4. Insert the power rear quarter glass latch onto the splined shaft of the power rear quarter glass latch regulator and on the rear quarter glass.
  5. Insert the retainer into the power rear quarter glass latch.
  6. Connect the power rear quarter glass motor electrical connector.
  7. Install the rear quarter glass trim.
  8. Install the rear quarter trim panel. See «REAR QUARTER TRIM»(ref-138783-S26712161962002042900000) .
  9. Connect the negative battery cable.
  1. Disconnect the negative battery cable.
  2. Gently pry the overhead console from the headliner.
  3. Disconnect the moon roof electrical connector from the overhead console, if equipped.
  4. Disconnect the rear quarter window switch electrical connector from the overhead console.
  5. Disconnect the map lamp electrical connector from the overhead console.
  6. Remove the overhead console.
  7. To install, reverse the removal procedure.
  1. Disconnect the negative battery cable.
  2. Remove the front door trim panel. See appropriate POWER DOOR LOCKS article.
  3. Disconnect the power window module electrical connector. (Scheme 20)
  4. Remove the four power window module screws. (Scheme 21)
  5. Remove the power window module from the vehicle.
  6. To install, reverse removal procedure.

Scheme 20

Scheme 20
Scheme 20

Scheme 21

Scheme 21
Scheme 21

Removal & Installation (Master Power Window Switch)

  1. Use a screwdriver to carefully pry the main power window switch from the driver-side door panel. (Scheme 22)
  2. Disconnect the main power window switch electrical connector. (Scheme 23)
  3. Remove the main power window switch from the vehicle.
  4. To install, reverse the removal procedure.

Scheme 22

Scheme 22
Scheme 22

Scheme 23

Scheme 23
Scheme 23

Removal & Installation (Right Power Window Switch)

  1. Use a screwdriver to carefully pry the passenger power window switch from the passenger-side door panel. (Scheme 24)
  2. Disconnect the passenger power window switch electrical connector. (Scheme 25)
  3. Remove the passenger power window switch from the vehicle.
  4. To install, reverse the removal procedure.

Scheme 24

Scheme 24
Scheme 24

Scheme 25

Scheme 25
Scheme 25

Removal & Installation (Rear Quarter Glass Switch)

  1. Remove the overhead console. See «OVERHEAD CONSOLE»(ref-138783-S13332898792002043000000).
  2. Remove the two rear power quarter glass switch screws. (Scheme 26)
  3. Remove the appropriate rear power quarter glass switch from the overhead console.
  4. To install, reverse the removal procedure.

Scheme 26

Scheme 26
Scheme 26
  1. Remove the rear quarter trim. See «REAR QUARTER TRIM»(ref-138783-S26712161962002042900000).
  2. Open the rear quarter glass. Remove the rear quarter glass latch-to-glass screw. (Scheme 27)
  3. Remove the two rear quarter glass hinge nuts and the rear quarter glass. (Scheme 28)
  4. To install, reverse removal procedure. Adjust rear quarter glass. See «REAR QUARTER GLASS»(ref-138783-S17020769932002042900000) under ADJUSTMENTS. Tighten the two rear quarter glass hinge nuts to 2.8-3.3 INCH Lbs. (3.8-4.5 N.m).

Scheme 27

Scheme 27
Scheme 27

Scheme 28

Scheme 28
Scheme 28
  1. Remove the rear quarter glass trim.
  2. Gently pry the two plastic retainers away from the power rear quarter glass latch.
  3. Remove the rear quarter glass latch-to-glass screw and the rear quarter glass latch. (Scheme 27)

Note. The power rear quarter glass latch can only be installed on the power rear quarter glass latch regulator one way.

To install, reverse the removal procedure. Tighten the rear quarter glass latch-to-glass screw to 2.8-3.3 INCH Lbs. (3.8-4.5 N.m).

  1. Remove the second row and third row seat belt upper anchor bolts.
  2. Remove the cover cap at the rear pillar from the rear quarter glass trim. (Scheme 29)
  3. Remove the rear quarter glass trim screw from the rear pillar. (Scheme 30)
  4. Use a pair of pliers to remove the two cargo net retainers from the quarter trim panel. (Scheme 31)
  5. If removing the left rear quarter glass trim: Remove the cover cap and left quarter trim panel center screw. Remove the two left quarter trim panel capped screws. (Scheme 32) Pull the top portion of the left quarter trim panel from the bodyside.
  6. If removing the right rear quarter glass trim, pull the top portion of the right quarter trim panel from the bodyside.
  7. Remove the push tab from the C-pillar lower portion of the rear quarter glass trim.
  8. Begin pulling the rear quarter glass trim from the rear pillar to remove it. (Scheme 33)or (Scheme 34)
  9. To install, reverse removal procedure.

Scheme 29

Scheme 29
Scheme 29

Scheme 30

Scheme 30
Scheme 30

Scheme 31

Scheme 31
Scheme 31

Scheme 32

Scheme 32
Scheme 32

Scheme 33

Scheme 33
Scheme 33

Scheme 34

Scheme 34
Scheme 34
  1. Disconnect the negative battery cable.
  2. Remove the left knee reinforcement plate.
  3. Remove the parking brake assembly in order to access the power window relay. See «1995 BRAKES FORD MOTOR CO. - DISC & DRUM»(ref-44590) article.
  4. Remove the power window relay. (Scheme 35)
  5. To install, reverse the removal procedure.

Scheme 35

Scheme 35
Scheme 35

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