I just found the VW service video that shows you how to do the job. It's on a mk4 but it's pretty much the same as the mk5 procedure. Make sure you download it and watch it (ignore the sound as it's in german) - it doesnt show you everything so also follow my instructions below:
http://rs298.rapidshare.com/files/16081 ... 6n_1_.mpeg
I wrote these instructions for somebody else ages ago - they reported back that they were perfect. It might be a little vague at points - I wrote it from memory so some bits may not be exact - they should be understandable though!
1. remove door card
with the chrome door handle pulled, insert screwdriver behind it so you can lever the plastic planel off that runs down the plastic door handle.
Unscrew the two screws that are behind this panel
Now unscrew the single screw that is at the leading edge of the door card, in front of the mirror
Now carefully put a large, flat headed screwdriver between the door and the door card to lever it off. I found the best place to start was the bottom corner (not hinge side). Lever it gently until you hear one of the plastic popper studs pop off. Work your way around the card until they have all popped. Although a certain amount of force is needed, dont be too aggressive as they can break with too much force.
Now lift the card up over the lock button while working it off the chrome door handle - hard to explain but obvious when you're doing it
Now disconnect any leads that go to the door buttons - windows buttons, mirrors etc. If its the drivers side, remember which order the two window buttons go
2. Remove the inner door membrane
Unscrew the speaker, disconnect and remove it.
Now take off the chrome door handle - it slides forwards (maybe backwards) to come off, and then disconnect the wire rod from the handle too
Remove the black plastic poppers from all round the door - they slide off of the white plastic bits that hold them in place. Have a carefull look at them to see what I mean.
Remove any plastic brackets so you can remove the membrane - you will see what i mean when you do it.
Now gently pull the edge of the membrane outwards and with a sharp blade score/cut through the sticky black stuff that holds it on. I actually just pulled mine off without cutting it but I ended up tearing it slightly in a couple of places. I left the bottom edge attached so it was easy to put back on again.
Unscrew and remove the speaker bracket
3. Remove the motor and regulator. (the regulator is the mechanism consisting of the two runners and the cables and the winder)
Please note - I may have one or two of these steps in the wrong order - namely the motor and winder removal bit - you may have to remove the motor from the regulatior bracket before the winder - the correct way will be apparant when you are doing it
There are four large nuts that need undoing - 1 on each corner of the regulator - remove these (it could even be 5 if theres one on the motor)
You should now be able to slightly move the whole mechanism, by hand, so you can reposition the motor part so it's accessible through the gaps in the metal door plate, with a screw driver - you might actually need a torx driver for this bit but can't remember (a torx has a 6 pointed star shaped end) - you will be able to see when you get to this point. DONT force the regulator too much as you will break the plastic bits that hold the clamps for the window. You will be able to manouvere it enough to get to it. What you are trying to do here is unscrew and free the winder mechanism from the actual motor. There are also white plastic spacers between the mechanism and the door (they might actually be between the bracket and motor so will be removed later, I cant remember - see below) - make sure these dont get lost when removing (and remember to put them back again when rebuilding). Once you have unscrewed it you will need to carefully prize it off with a screwdriver making sure that the wound cable stays within the body of the winder.
Once you have disconnected the winder from the motor you will be able to manually push the window down by hand. you need to do this so you can undo the clamps that hold the window in place. As the window comes down you will be able to see a clamp either side. When each of the clamps line up with a hole in the metal of the door frame you will be able to unscrew them using a nutdriver, so you can release the window. Once unscrewed, lift the window back up out of the clamps to a closed position (by lifting from the bottom edge of the window).
You now need to tape the window in place to stop it falling down. This is best done with two people but I managed it on my own by wedging a piece of wood under the window to hold it in place (wood needs to be roughly the right length to wedge between the bottom of the door and the window). Tape all around the window using electrical tape (masking tape might work too) making sure you press it down very firmly all round, making contact with both the window and door frame. Now manouvere the regulator so you can remove it. When you can get to the connector on the motor, disconnect it - you may be able to do this at an earlier stage than now. Be warned - this connector can be a real b*tch to get off. Its just a larger version of the speaker connector so make sure you understand how it works by studying the speaker one before attempting to remove it. You may be lucky and it might come off easily for you - I hope it does.
Now lay the regulator out on the ground - it's the easiest way to work with this.
Remove the motor from the regulator bracket. Again I think you need a torx driver for this. There are also white plastic spacers between the regulator bracket and the motor (they might be between the bracket and the door - cant remember) - make sure these dont get lost when removing. Remember the above procedure might be to remove the motor first before the winder while the regulator is still in the door. It can only be done one way so you'll work it out! once you have removed this you can then unscrew the gold coloured plate from the motor - behind this is the cog that you are replacing. Remove the old cog.
Now follow the instructions included with the repair kit to add the silicon grease to the new cog.
Putting everything back together is pretty much a reversal of everything you have already done.
Put the motor back together. Connect the winder back on to the motor.
At this point I actually connected the motor back to its electrical harness and reconnected the switch to make sure the repair had worked and that the motor now turns and makes the regulator clamps go up and down - you will figure out how to best do this yourself! You will need to disconnect them again when tested.
Now screw the motor and winder back on to the regulator bracket. Now manouvere the regulator back into the door. Now put the 4 (or 5) nuts back each corner. Best not to do them up too tightly yet as you may need to slightly reposition things.
Once its back in connect the motors electrics harness back up.
You might now need to connect the switch again so you can get the clamps in the right posisiton. Once the clamps are in a place where they are accessible with nutdriver, take the tape off the window and lower it into the two clamps and tighten them back up again. Now make sure it all works without binding up anwhere. When satisfied, tighten everything up.
Screw the speaker bracket back in
Put the door membrane back on
Slide the popper studs back on
Reconnect the speaker and screw in
reconnect the door handle and reattach to door
reconnect all buttons to door card
Put door card back on, over lock button making sure you oput the door handle throughWhen in place, push firmly all round edges to make sure it pops back on to the studs at all locations
Put the 3 screws back in (2 in handle, 1 at front)
And you should be good to go!
Good luck - report back to the forum on your results and correct my instructions if any of them were wrong
Cheers
Marc