Rear Window Overview
Rear Window Overview
1 Rear Window
• Distance - a - to roof = 2.5 mm
• Center the distance - d - to the "D-pillar" = 3 mm.
• Before removing, disconnect all electrical connectors and secure the terminals to the middle of the window on the inside using adhesive tape.
2 Adhesive Sealing Material
• Bead width = 8 mm ± 2 mm
• Bead height = 12 mm ± 2 mm
• Distances to the window edge:
• Dimension b = 15 mm
• Dimension c = 24 mm
• Dimension e = 16 mm
3 Spacer
• Make 3 markings each on the top and bottom edges of the window.
4 Adhesive Stop Profile
• Distance to the edge of the window dimension f = 24 mm
• Bond the adhesive stop profile directly by the window defroster distributing wire.
• Window adhesive must not come into contact with the rear window defroster distributing wire.
Undamaged Rear Window, Removing
Special tools, testers and auxiliary items required
• Cutting Tool Kit (VAS 6452)
• Wire Spool (VAS 6452/1)
• Electric Cutter (V.A.G 1561A)
• Knife (V.A.G 1561/10)
• Scraper (25 mm) (V.A.G 1561/8)
• "C-pillar trim" removed.
• The high-mounted brake lamp is removed.
- Disconnect rear window defroster and window antenna connectors and secure to center of window with adhesive tape.
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.
- Poke the awl - 2 - through the bead of adhesive from the inside to the outside as illustrated.
- Cover the awl outlet under the body flange with tape - 1 - to prevent damaging it.
- Feed both cutting wire ends - 3 - into the awl and pull it in.
The ends of the wire must not be twisted when cutting through the adhesive - arrow -.
- Route cutting wire around rear window under the glass as shown in the illustration.
- Mount both spools on the inside of the windshield as illustrated.
- Insert an additional guide awl 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.
- 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 rear shelf.
- Cut the window free first in the lower area.
- Cut the lower window at the D-pillar free.
- Position the guide ring as shown and cut upward further in the area of the D-pillar.
- Move the spool and the guide awl as illustrated and cut free the section along the opposite lower D-pillar.
- Move the reel device as illustrated and install the guide awl.
- Cut top of window free.
- Move the reel device as illustrated.
- Cut the window free on the right upper corner.
- Move the window glass over to the left corner of the window and cut the window free.
- Move the left reel device to approximately the center of the window as illustrated and mount the guide awl.
- Cut the window free along the top to approximately the center of the window.
- Move the right side reel device over the left one as illustrated and cut free the window completely.
- Lift the window out of the rear lid using the suction cups.
Damaged Rear Window, Removing
When removing a window, always wear protective goggles and leather gloves.
- Protect body and interior from glass splinters.
- Remove glass pieces from adhesive material.
- Disconnect rear window defroster and window antenna connectors.
- Bond flange all around with fabric reinforced adhesive tape.
- Remove adhesive material (with glass residue) from window opening using (V.A.G 1561A) and (V.A.G 1561/10) (with stopper roll).
Preparations for the Installing the Rear Window
• 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 window all around in adhesive area using Cleaning Solution (D 009 401 04).
• Ceramic application on window is not primer.
• It must be primed before the application of adhesive sealing material!
- Apply the glass/paint primer (D 009 200 02).
Applying Primer:
- Apply the glass/paint primer - 3 - to the adhesive surface on the glass - 4 - evenly and in a single stroke using the applicator - 2 -.
- Beginning applying with saturated felt.
• Drying time 10 minutes
Glass/paint primer conducts electricity and must not touch rear window defroster distributing wire.
Window Flange:
- If the window flange was damaged, paint structure must be recreated and if necessary, perform corrosion protection measures.
- First clean corrected area with cleaning solution (D 009 401 04) and then apply glass and paint primer (D 009 200 02).
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 ± 2 mm
• Dimension - b - = 12 mm 2 mm
• Dimension - c - = pay attention the distance to the edge of the glass.
- Position the entire nozzle surface - 2 - on the window.
• Application direction - arrow - for adhesive bead - 1 -.
- Apply adhesive sealing material all around.
- With an undamaged removed window, apply adhesive to remaining bead.
- Insert the rear window into window cut-out using suction cups.
The window must be installed within 15 minutes or the adhesive sealing material will not adhere properly.
- Center window along sides.
- Note distance to upper lid edge = 2.5 mm.
- Observe minimum curing time => [ Minimum Curing Time ] Flush-Bonded Windows.