Rear Window
Flush-Bonded Windows
Rear Window
Removing
Undamaged Rear Window, Removing
• The C- and D-pillar trim panels are removed.
• Auxiliary brake light removed.
- Disconnect rear window defroster and window antenna connectors and secure to center of window with adhesive tape.
CAUTION!
When removing a window, always wear protective eyewear and leather gloves.
- From the (VAS 6452/1), pull out approximately 6.5 meter of cutting wire (about 6 turns) and cut it.
- Cover the awl outlet under the body flange with tape - 1 - to prevent damaging it.
- Feed both cutting wire ends - 3 - into the awl - 2 - and pull it in.
- Place the cutting wire all the way around under the rear window as illustrated.
- Route cutting wire around rear window under the glass as shown in the illustration.
CAUTION!
The ends of the wire must not be twisted when cutting through the adhesive - arrow -.
- Mount both spools on the inside of the windshield as illustrated.
- Insert the ends of the cutting wire- 1 - into the spool - 2 -
- Tension the cutting wire using the spool - 1 - and insert the plastic film - 2 - taken from the (VAS 6452) to protect the wire and the instrument panel.
- Cut the first section open, while doing this, the wire is guided into the integrated roller - arrow - on the spool
- Insert an additional guide awl - 2 - into the adhesive and secure it to the windshield with the suction cup as illustrated to make sure that the wire runs as close to the windshield as possible.
- Move the spool and the guide awl as illustrated and cut free the section along the D-pillar.
- Move the spool and guide awl as illustrated.
- Cut free the windshield further up to about the center.
- Cut free the lower section of the windshield with the second spool
- Move the spool upward and insert the guide awl as illustrated.
- Cut free the windshield along the D-pillar upward.
- Move the spool over the center of the windshield as well as over the first spool as illustrated and cut free the rest of the windshield along the top.
- Remove window with double suction cups.
• When removing a window, always wear protective eyewear and leather gloves.
- Remove the rear shelf.
- Pull off or screw off connections for rear window defrost and window antenna.
- Press connections on window towards center of vehicle.
Damaged Rear Window, Removing
CAUTION!
When removing a window, always wear protective eyewear and leather gloves.
- Protect body and interior from glass splinters.
- Remove glass pieces from adhesive material.
- Disconnect connector - 1 - for antenna and amplifier.
- Disconnect window heater connections.
- Bond flange all around with fabric reinforced adhesive tape.
- Remove adhesive sealing material (with glass residue) - 1 - from window opening using electric cutter and knife (V.A.G 1561/11) (with stopper roll).
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.
- Make sure the distance to the edge of the glass is 16 mm all around.
- Using two double suction cups, install rear window in window opening.
CAUTION!
The window must be installed within 15 minutes or the adhesive sealing material will not adhere properly.
- Center window along sides.
- Distance from the edge of the windshield to the roof frame.
- Observe the minimum curing time. Refer to => [ Minimum Curing Times ] Minimum Curing Times.