I have the regulator out of the door. All the cables and clips replaced in the correct positions. Now I have to "load" the drive pulley cog with the cables. So one is all the way out and one is wound round the cog. How do you know how much tension is required? I seem to have it too slack and not enough free to go round another turn on the drive pulley? I am stumped.

Anyone done this?

I know this won't help, but buying a regulator new instead of a 'repair kit' saved me alot of hassle and was only £20 from eBay.

 

 

I second a new unit over repair kit I have a oem spec window reg in my drivers side and its faultless.

I did a repair kit on my mk4 golf which is probably much the same, Cant remember it being to much of an arse. I think I wound them round the cog and then clipped in the cables to the steel guides using brute force and ignorance. Doing it again I would probably spend the extra £12 and get a full reg. 

I have figured out that you cannot do this single handed. There are two springs on the bowden cables and these provide the tension but these go in either side of the winder cover so need compressing - that's two hands. The other hand has to pull the cable over the last pulley where it can be adjusted with the slotted plastic fitting onto the frame.

I am worried that the motor is not in the up or down position or is it an automatic system so the motor runs until it feels resistance and then stops/reverses? If it is fully "up" and the cables are in the fully down position will it snap something?

Motor can be at any point.