S2 Coupe Leccy Window Cable Repacement

[audimaniac]

Recently tried replacing my Drivers door cables and got in a bit of a tangle Upon installation, the cables jammed and found out afterwards that my motor was partially seized up of which i have now sorted but have now been left with mishaped cables of which, i have straightened to a degree but now i am struğling to get the thing back together, whichever way i try, i am left with excess cable to the motor My questions are, is there a definitive way to set these cables up?? Does the window have to be right at the top?? or bang at the bottom?? and which cable goes to which side of the motor grooved yellow wheel??? Any help will be greatly appreciated, pics also attached.

[audimaniac]

Help anyone??

[Greg_S]

I'll see of the there is anything in the Haynes manual. I need to take this myself at some point

[montyrs2]

Is the cable fully wound around the cable drum in your pictures?

I'd suggest taking the door card off the other side so you can see which exits are used. Looking at your pictures it doesn't look like you have much cable length to loose. Adding curvature to the cables in a sheath will also take up cable length so be sure to make sure that the cable routing is as intended.

The big one is to make sure the cable is would around the drum in the right direction. The motor is a simple two wire motor which changes direction when the polarity of the wires is changed. Obviously is you wind the cable on the worng way the window will go in the opposite direction.

The S2 system doesn't know the position of the glass due to the lack of a hall effect sensor in the motor so it shouldn't matter if you set it up with the sliders in an up or down position.

I've not examined mine in detail but I would imagine that there is a hard stop in the up position. I.e when the glass goes up the two sliders hit a stop to put the glass into the fully up position. It is possible that lower position does not have a hard stop so you could end up setting up the sliders higher or lower to each other.

Hopefully that made sense. Have a look for a proper hardstop top or bottom don't just assume that if you put the silders all the way one way or the other they will be in the right place relative to each other.

I have a huge amount of slack in my system and it seems to be working ok so I wouldn't worry too much about some excess cable.

Hope that helps.

[Audicted]

Have you taken a look at this? http://20v.org/winder.pdf

[johne]

My questions are, is there a definitive way to set these cables up??

Yes!

Does the window have to be right at the top?? or bang at the bottom??

Neither, I seem to remember it goes somewhere in the middle. There are some old posts detailing the challenge, one with photos iirc.

This post may help you in the right direction:

http://www.s2forum.com/forum/showthread.php?t=35260&highlight=window

and you need an 11mm socket with a slot cut down it's side

John

[Error404]

I did this years ago and remember it was a real pain in the ***. The whole thing is a poor design IMHO, the frame is not rigid enough and the cable pulleys seize and break. I would clean all of that sticky old grease out and take the opportunity to lube it up with fresh grease.
As Monty said I suspect you have not wound the cable around the drum correctly. Two of the cable sleeves on the motor housing are unused. From memory the cable exists on the one which is roughly opposite the entry.
Once the wire is tangled & kinked it is very difficult to get to fitted correctly again, but it is possible. In terms of setting the window mech up, doesn't matter where abouts in the opening range it is but you must get the cable as tight as possible and that the glass guides are level on the frame. A small pair of mole grips helps to hold the cable as you tension it.
HTH