Service Procedure

SERVICE

Tip: Replace only the affected window regulator; it is not necessary to replace both window regulators.

Determine whether the new repair kit is necessary





Before ordering the repair set, use a VAS diagnostic tester to determine the part number of the door control unit.

^ If the part number is 8T0 959 793 J (or higher index) for the drivers side or 8T0 959 792 J (or higher index) for the passengers side, the entire repair set is not necessary. Only a new window regulator is necessary.

^ If the part number of the door control unit is 8K0 959 792, 8K0 959 793, 8K0 959 792 H or 8K0 959 793 H, order the complete repair set (comprised of a new window regulator mechanism, door control unit and outer door seal).

Complete modifications necessary to install the new repair set





1. The attachment of the Bowden cables to the door shell has changed. Originally the upper cable was secured to the door shell using a double clip (see Figure 2) mounted to the inside of the door shell.





Remove the clip.





2. The upper cable on the replacement window regulator has a clip that will be inserted into the hole labeled "A" Figure 4.

If hole "A" is not present in the door shell, use the upper hole labeled "J" in Figure 4.

Note which hole you will use.

3. The improved window regulator is fitted with a second clip on the lower cable that must be attached to the door shell. It will attach to a hole near the lateral acceleration sensor. This hole has been in the door shell since mid-2008 production.

Determine if the hole is present. If this hole is not present, the hole must be drilled.





a. Remove the side airbag crash sensor in the door to establish the position of the hole.





b. Using the edges of the opening for the side airbag crash sensor as a guide, draw perpendicular lines as shown in Figure 6.

A: 18mm
B: 27mm
Hole diameter: 6.5mm

c. Drill and deburr the hole.

d. Apply Anti-Corrosion Wash Primer ALN 002 003 10 with a brush and allow to thoroughly dry.

e. Treat the surface with Anti Corrosion Wax D 308 SP5 A1.





Note:
Use caution not to allow any wax to come in contact with the lateral acceleration sensor.

f. Close the hole used by the original window regulator with Bung N 909 826 01.

Install the entire repair set

^ Make sure to install all components of the repair set.

Tip: Door control units with indexes below "J" installed with the improved window regulator will malfunction.

^ An additional bolt WHT 004 905 will be required. This bolt is not included in the repair set. One bolt per door is required.

^ In some cases the door seal provided in the repair set may need to be modified slightly.

Depending on the VIN of the vehicle, there are two possible door profiles.





The replacement seal may have a notch that will need to be cut to accommodate the door profile shown in Figure 8.