http://www.tigerstyle.co.uk/poloforum/v ... hp?t=14965
http://www.tigerstyle.co.uk/poloforum/v ... hp?t=14363
http://www.tigerstyle.co.uk/poloforum/v ... hp?t=30319
window motor cog repair kit
http://www.tigerstyle.co.uk/poloforum/v ... hp?t=28649
http://www.tigerstyle.co.uk/poloforum/v ... php?t=2619
Earth connector problem
http://www.tigerstyle.co.uk/poloforum/v ... hp?t=30761
Switch problem
http://www.tigerstyle.co.uk/poloforum/v ... hp?t=12560
The problems with my window is like this:
1) When closing the window, it would stop at the middle of closing and then drop down a bit and then stop, i need to keep clicking the switch repeatly bit by bit to get the window fully closed.
2) I also had several occasion after fully open the window, it just stay there and does not want to go up. After a few close and open maneuveur it would then go up again but still with the same "stop at middle and then down a bit problem".
If u had problem like (1) above it's most likely a window lifter/regulator (plastic clip) problem.
Window lifter/regulator (clip) problem
I remove the doorcard and found that one of the plastic clip has a broken leg, and the window clamp with the front part of the window glass seems tilted a bit forward.
The other clip seems to be ok
The lost of one leg of the plastic clip result in a slight malalignment of the window glass which probably lead to problem (1) above.
Before u order the "cog repair kit" - 6N3 998 801A (more details below), i'd suggest u take out the regulator and fully examined both plastic clips. I order a "window lifter without motor" for front passenger side (6N4 837 461B) and replaced (procedure below). There are other diy clip-repair method from the related posts listed above that may worth a try.
Actually I had the above problem for my driver side front window within 2 months after delivery of my car in 2001 and replaced window lifter by warranty. Afterwards I stick with 2 rules on my driver side window which is still running good now. The rules are: 1) never close door with the window open; 2) don't open the window down to the bottom completely.
Removal of the window lifter/regulator allow me to examine both plastic clips fully. By fliping the glass clamp/plastic clip assembly i noticed that actually the other plastic clip is actually also broken comparing with the other side!
u see from the pics that the plastic clip is actually secure to the running wires by a smaller metal piece reinforcement, normally the clip should move with the wire together. My other clip is broken at the inner side which allow the wire to disengaged from the clip.
This probably lead to my window glass not responding to a close command after fully open (problem 2)!
Window motor cog repair kit
The kit I've ordered - 6N3 998 801A (but not used) is like this, a white cog which is used within the window motor assembly, grease, instruction for greasing the cog, and a 2pin wire with connector which is not use on my 6N2 polo GTI.
If u are sure that both plastic clips are intact. u can try open window motor cog to see it had a cog spindle with smoothed/bent teeth inside. Loose the torx screws 3 (red arrows) on one side and 5 (white arrows) on the other side like pics below.
If the teeth of the cog spindle inside the window motor assembly is smoothed or bented u need this kit for replacing. This probably would cause your motor grinding the spindle without much window glass movement.
Other than the window lifter/regulator and the window motor cog spindle problem. Other cause of fail window are electrical like switch malfunction, fuse, relay, earth spade connector (see post link above); and finally the most expensive window motor problem, which i don't had much experience with.
Procedure to replace window lifter/regulator:
1) remove door card, front speaker and the foam padding (for 6N2 - http://www.tigerstyle.co.uk/poloforum/v ... hp?t=32888)
2) remove the inner window slot seal just pull up from rear end 1st (red arrow).
3) lower the window glass so that u can loosen the two bolts (red circle below) clamping the window glass.
4) lift the the window glass with a bit of front tilting and take the window glass upward away from the slot.
5) just loosen the 10mm hex bolts (total 5 in 6N2, red arrows above) of the window lifter/regulator a bit (no need to take out the bolt), lift window lifter slightly up so that bolt can be pulled through installation openings.
6) disconnect the electrical connector for window motor
7) the whole lifter/regulator can now be negotiate into the large opening at lower part of the door and take out.
separate the motor assembly from the window lifter/regulator, by loosen 3 torx and 5 torx screws as above pics Reverse the procedure for installation
Cheers
Andrew