Windshield
Windshield
Special tools, testers and auxiliary items required
• Wire Spool (VAS 6452/1)
• Electric Cutter (V.A.G 1561 A)
• Scraper (25 mm) (V.A.G 1561/8)
- Remove the windshield wiper arms.
- Remove the plenum chamber cover. Refer to => [ Plenum Chamber Cover, Vehicles from 06.08 ] Plenum Chamber Cover, Vehicles From 06.08.
- Remove the left, center and right sun visors.
- Remove the interior rearview mirror.
- Remove upper A-pillar trim on left and right.
When removing a window, always wear protective goggles and leather gloves.
- From the (VAS 6452/1) , pull out approximately 6.5 meters 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.
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 the awl approximately to the center of the windshield.
- Cut free the windshield up to about the center.
- Cut free the bottom 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 over the first spool as illustrated and cut free the rest of the windshield along the top.
- Remove the windshield from the vehicle with the suction cups.
Preparations for Installing the Windshield
- When reusing the undamaged window, cut rest of adhesive material on window and flange with (V.A.G 1561 A) and (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.
• 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 adhesive surfaces all the way around with cleaning solution (D 009 401 04).
- Apply Glass and Paint Primer (D 009 200 02) as described below.
Ceramic application on window is not primer! It must be primed before the application of adhesive sealing material!
Applying Primer
- Apply glass-/paint 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.
• The glass/paint primer must be positioned in the center of the 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 the corrected area with cleaning solution (D 009 401 04) and then apply glass/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. Glass/paint primer
3. Window
• Dimension - a - = 8 mm
• Dimension - b - = 12 mm
• Dimension - c - = note varying spacing dimensions to window edge => [ (Item 2) Adhesive Sealing Material ] Windshield Overview.
- 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 suction cups, install the windshield.
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 => [ (Item 1) Windshield ] Windshield Overview.
• Secure the window to the top of the roof with adhesive tape.
- Before installing plenum chamber cover, first remove protective profile - 2 - from the frame.
- Observe minimum curing time => [ Minimum Curing Time ] Flush-Bonded Windows.