Windshield

Windshield

Removing

Necessary tools and materials => [ Flush-Bonded Windows ] Description and Operation.

CAUTION!
Always wear protective glasses and leather gloves when removing a window.

- Remove wiper arms.

- Remove cowl panel trim.

- Pull left and right drip rails out from retaining strips (from bottom upward).

- Remove left, middle and right sun visors.

- Remove interior rear-view mirror.

- Remove trim on top of A-pillars.

- Pierce hole in adhesive sealing material from inside of vehicle using awl (V.A.G 1755) or awl (V.A.G 1351) at bottom-left of windshield.





- Pull cutting cord through adhesive sealing material into inside of vehicle using awl.

- Lay cutting cord underneath and all around inside of windshield.





- Secure end of cutting cord at bolt - arrow - for securing window wiper frame.





- Insert protective foil (V.A.G 1474/13) between windshield and instrument panel.

- Secure beginning of cutting cord in winding device and cut out first area of adhesive (up to about center of windshield).





- Move spooling tool as shown in diagram and continue cutting.





- Move spooling tool as shown in diagram and attach relay pulley.





• Route cutting cord as shown.

- Cut adhesive up to point where cord no longer runs in relay pulley.

- Remove relay pulley and continue to cut adhesive.





- Move spooling tool as shown in diagram and attach relay pulley in upper corner of window.





• Route cutting cord as shown.

- Insert protective foil (V.A.G 1474/11) between windshield and molded headliner.

- Cut adhesive up to point where cord no longer runs in relay pulley.

- Remove relay pulley and continue to cut adhesive.

- Repeat these steps in top left and bottom left corners of windshield.

- Cut window completely free.

- Remove window using two double suction cups.

Preparing for Window Installation

• If windshield flange was damaged during removal, paint structure should be repaired according to specifications in Repair Information, "Vehicle-Paint " and if necessary, corrosion repair measures should be taken according to guidelines in "Surface Technology/Chemical Materials Folder".

For undamaged removed windshield

- When reusing an undamaged window, cut back smoothly residual adhesive sealing material on window and flange using electric cutter (V.A.G 1561A) and scraper (V.A.G 1561/10); do not remove completely!

- Residual material acts as a base for the new adhesive sealing material.

CAUTION!
• Keep adhesive surface free of dirt and grease.

• Only cut back adhesive surface shortly before installation.

• Do not prime or use a cleaning solution on the adhesive surface.

New window, installing

- Clean windshield in adhering area using D 009 401 04 and prime using D 009 200 02 glass/paint primer.

Applying primer

- Apply primer - 2 - along circumference evenly and in one motion using applicator - 1 -.





- Begin application with a fully saturated felt. Air drying time approx. 10 minutes.

• Primer dimensions: Dimension - a - = approx. 20 mm

- Apply primer in center of adhesive bead.

CAUTION!
Ceramic application on window is not primer! It must be primed before the application of adhesive sealing material!

Dimensions for application of adhesive





1 Adhesive bead
2 Primer
3 Washer

• Bead width - a - = 8 ± 2 mm

• Bead height - b - = 12 + 3 mm

• Dimension - c - = note varying spacing dimensions to window edge.

Installing

- After preparatory work has been performed, apply the adhesive.

- Position complete surface of nozzle - 2 - onto window.





- - Arrow - indicates direction of application

• Cross-section thickness of adhesive bead - 1 - is determined by dimension of opening in nozzle tip and rate of application.

- Apply adhesive sealing material all around, as shown in illustration.





- Note varying spacing dimensions to window edge.

- Using two suction lifters, install windshield in windshield opening.

CAUTION!
Window must be installed within 15 minutes, otherwise bonding properties of adhesive will be impaired.

- Align windshield at sides.

- Spacing between edge of window and roof frame must be 6 mm + 0.5 mm.

- Press drip rail - 1 - into retaining clips - 2 - until it stops only after curing time has elapsed.





- When pressing in drip rail, make sure sealing lip - arrow - lies flat against windshield and does not slip behind edge of windshield.

- Affix stickers on windshield (e.g. for airbag) in same position on new windshield. "Caution- Safety information" sticker





• Dimension - a - = 25 mm

• Dimension - b - = 10 mm