This is the diagram from my manual for a 1990 S4


[Would a Mod please move the thread to the Classics lounge]

 

Thanks. I have this diagram but it is for the manual window regulator. The power window regulator setup only has two pulleys top and bottom and, of course, the cable is routed around the windlass drum that is operated by the electric motor. It's the routing and particularly the threading around the drum that is a my dilemma.

 

Update - I believe I figured out the proper routing for the cable although the diagram in the Alfa shop manual under the power window heading is identical to the diagram shown next under the manual window regulator and has more pulleys than my 86 power window regulator setup. I measured the old OEM cable and cut my new cable to that length but installing the new cable with nothing spooled on the windlass drum results in way too much slack in the cable. Without detailed instructions I reasoned that there must be a prescribed number of prewindings on the spool so that when the cable is routed properly it has the proper tension. What I don't know is how many windings to make and whether those all should be one end or the other or some combination. It seems that the ideal end state would be that neither the upper or lower end of the cable on the drum should ever come to the very end, else over time metal fatigue would result in bending the cable ends where they pass through the holes in the spool causing them to eventually break like mine did when I got into this mess. Does anyone know how many prewinds to make on the spool so as to end up with the proper installation of the regulator cable?

 

Having had a wire cable birds nest of an issue on my 1984 Spider Veloce, and countless hours of frustrating almost got it, and then the wire cable goes nuts and goes every way but where I want it, repeat,repeat,repeat, I made a too tool to make this problem solve easily.
First I've got the wire cable transmission spool in hand and have the cable wound in 2 directions, evenly spaced and ready to slip into the transmission housing / electric motor assembly, when suddenly it all unwinds and turns into a birds nest once again.
After repeating this multi times, I concluded there is a better way.
Went to the hardware store's plumbing aisle, and spent $3 on a universal, copper, sink down tube to the S trap .
From this I hacksawed a 4 inch long 3/4 inch wide section that looks like the letter C.
I also had ready 2 zip ties.
Back to the Alfa door, and spool in hand once again did the windings in 2 directions, carefully balanced and even distribution of the wire on the spool, and before trying to sneak the spool back into it's transmission / motor housing, I slip the copper C clamp around the spool and secure it, and the double cables, onto the spool with the 2 zip ties, and trim the zip ties to length.
Tada !
A stable assembly that I can now leisurely slip into the transmission / motor without it flying apart !
I then routed the cable in the zig-zaggy way it has to be, and when all looks reasonable, I cut the zip ties off and voila , ready for 12v DC to the motor.
A little adjustment of the pullies and Jeb's a millionaire !
You are very welcome.
Don Jamieson,
Duncan,
Vancouver Island,
B.C.,
Canada.