Windshield

Flush-Bonded Windows

Windshield

Removing

Preparatory Steps

- Remove windshield wiper arms.

- Remove cowl panel trim.

- Pull left and right water deflectors out from retaining strips (from bottom upward).

- Remove the left, center and right sun visors.

- Remove the interior rearview mirror.

- Disconnect all electrical wires to sensors and rearview mirror or to window heater.

- Remove the A-pillar upper trim.

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.

- Poke the awl through the bead of adhesive from the inside to the outside as illustrated.





- Feed both cutting wire ends - 3 - into the awl - 2 - and pull it in.

- Place the cutting wire all the way around under the windshield as illustrated.





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 and place the protective foil - 2 - between the instrument panel and the wire





- 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.





- If necessary, move the protective foil - 3 - along with the wire and cut the windshield free with the spool - 1 -.

- Move the spool and the guide awl as illustrated and cut free the section along the A-pillar.





- Moved the spool and guide awl approximately to the center of the windshield.

- Cut free the windshield 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 A-pillar upward.





- Move the spool over the center of the windshield as well as the first spool as illustrated and cut free the rest of the windshield along the top.





- Remove the windshield from the vehicle with the double suction cups.

Installing

Preparations for Installing the Windshield

- When reusing the undamaged window, cut rest of adhesive material on window and flange with Electric Cutter (V.A.G 1561 A) and Scraper (25 mm) (V.A.G 1561/8) so it is even, but 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.

With New Window

- Clean window all around in adhesive area using Cleaning Solution (D 009 401 04).

- Apply Glass and Paint Primer (D 009 200 02) as described below.

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

Applying Primer





- Apply primer - 3 - with applicator - 2 - evenly in one stroke near the window molding - 1 - on the window - 4 -.

- Beginning applying with saturated felt.

• Primer width approximately 20 mm.

• Apply primer in center of adhesive bead.

• Curing time 10 minutes

Window Flange

- If the windshield flange was damaged, then it must be repainted and if necessary, corrosion protected.

- First clean corrected area with Cleaning Solution (D 009 401 04) and then apply Glass and Paint Primer (D 009 200 02).

Windshield, Installing

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

Dimensions for adhesive application:





1. Adhesive sealing material

2. Primer

3. Window

• Dimension - a - = 8 mm

• Dimension - b - = 12 mm

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

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





• Application direction - arrow - for adhesive bead - 1 -.

- Apply adhesive sealing material - 1 - all around on window - 2 - according to illustration.





- With an undamaged removed window, apply adhesive to remaining bead.

- Using double suction cups, install the windshield.

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.

• Secure the window to the top of the roof with adhesive tape.

- Press drip rail - 1 - into 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.

- Apply labels on windshield (for example, for airbag) in same position on new windshield.

"Caution - Safety information" label





• Dimension - a - = 25 mm

• Dimension - b - = 10 mm

- Before installing plenum chamber cover, first remove protective profile - 2 - from clamping strip.

- Observe minimum curing time. Refer to => [ Minimum Curing Times ] Minimum Curing Times.