Windshield: Service and Repair
WM 641219 Removing and installing windscreen
Technical values
Preliminary work
1. Remove interior rear-view mirror. -> 682719 Removing and installing interior rear-view mirror - section on "Removing" 682719 Removing and installing interior rear-view mirror
2. On vehicles with a rain sensor: Remove the rain sensor. -> 921219 Removing and installing rain sensor - section on "Removing" Service and Repair
3. On vehicles with a telephone: Remove antenna for telephone. -> 919019 Removing and installing control unit for telephone - section on "Removing" 919019 Removing and installing control unit for telephone
4. Remove cowl panel cover. -> 508719 Removing and installing cowl panel cover - section on "Removing" Service and Repair
5. Remove roof joint cover strips at the left and right. -> 663619 Removing and installing roof joint cover strip - section on "Removing" 663619 Removing and installing roof joint cover strip
6. Remove A-pillar trim panel at the left and right. -> 705719 Removing and installing A-pillar trim panel - section on "Removing" 705719 Removing and installing A-pillar trim
Technical values
Gap dimensions of windscreen
=> Gap dimension: 1 mm+/-1 mm
Gap dimension
=> Gap dimension: 3 mm+1 mm
Gap dimension
Tools and materials
The following tools and materials are required for removing and installing the windscreen with 2-component adhesive:
Removing windscreen
Installation position of windscreen
1. Lift up the sun visor slightly and unclip it from its holder -A-.
Removing sun visor from its holder
2. Swivel out the sun visor -B-.
3. Open cover for sun visor holder.
Opening cover
4. Unscrew fastening screw -1- securing sun visor holder.
Removing sun visor holder
5. Unclip cover for sun visor base using an assembly wedge.
Unclipping cover
6. Unscrew fastening screws -1-.
Detaching sun visor mounting
7. Unclip roof trim panel from the fastening clips close to the sliding roof aperture. (Only on vehicles with a sunroof)
8. Detach the roof trim panel.
Lowering the roof trim panel
8.1. Unscrew and remove fastening screws -1- ( -A- ).
8.2. Carefully lower the roof trim panel -B-.
WARNING
Vehicle windows removed and installed incorrectly
- Danger of cuts
- Risk of eye injuries
-> Wear personal protective gear.
-> Always shut off power supply when replacing cutting knife.
9. Separate windscreen.
9.1. Removing windscreens with the cutting wire separating device.
Information
- The procedure for removing car windows is described in -> 6X00IN General information on removing car windows 6X00IN General information on removing car windows.
Preparing window aperture for installation
1. Remove adhesive from the body.
1.1. When removing remaining adhesive -1- with the cutting tool -C- and the flashing knife -D- on the body, ensure that only a surface coating of adhesive remains -2-.
Information
- The surface coating of adhesive residue helps new adhesive to stick. Keep cut surfaces clean and free of grease and do not clean with cleaning solution.
2. Clean and prime paint damage or newly built-up paint areas in the window aperture of the body.
2.1. Clean new paint areas or damage to the top coat paint in the non-visible area of the window aperture in the body with cleaning solution -H1- and touch up with primer -H2-.
Information
- A ventilation period of at least 10 minutes must be observed between the cleaning of the glass section and the application of the primer! No cleaning solution residues may remain on the body.
Preparing windscreen for installation (re-installation only)
Information
- The removed windscreen can be reinstalled if there was no prior damage to the windscreen and the windscreen was removed without damage.
1. Clear away adhesive on the windscreen.
1.1. Fit cutter -C- with the flashing knife -D- and remove remaining adhesive from the windscreen, ensuring that a surface coating of adhesive remains.
Information
- The remaining adhesive helps new adhesive to stick. Keep cut surfaces clean and free of grease and do not clean with cleaning solution.
2. Check the foam element around the chassis number for damage and replace it if necessary.
3. Activate the bonding section of the windscreen.
3.1. During long idle periods, apply activator -H3- to the remaining adhesive.
4. Check the seal at the top of the windscreen for damage and replace it if necessary.
Seal on windscreen
5. Stick seal to the top of the windscreen.
Preparing windscreen for installation (new windscreen)
1. Clean and prime the window.
Cleaning and priming windscreen
1.1. Clean the window glass with cleaning solution -H1-.
1.2. Apply primer -H2- to the glass flange close to the marking.
Information
- A ventilation period of at least 10 minutes must be observed between the cleaning of the glass and the application of primer! No cleaning solution residues may remain on the windscreen.
Installing windscreen
Information
- The removed windscreen can be reinstalled if there was no prior damage to the windscreen and the windscreen was removed without damage.
Information
- Two persons are needed to insert and adjust the windscreen.
CAUTION
Danger of material damage if specified curing time of adhesive is not observed! In order to ensure that the bonded joint is sufficiently strong, the following boundary conditions must be adhered to:
- The vehicle must not be used until the curing time has elapsed.
- Curing time: 3 hours
- Temperature: at least 10 °C
- Fixing time: approx. 1 hour
->
1. Prepare 2-component bonding material for processing. -> 6X00IN Processing of Porsche 2-component window adhesive
Information
- The adhesive has an open time of -15 min- , which means that the bonding material must be applied and the car window must be assembled within this period of time.
- In order to ensure that the substance is completely mixed, apply a 30 mm long adhesive bead of fresh adhesive to a piece of cardboard before processing.
Information
- When applying the adhesive, it is essential to ensure that the adhesive bead overlaps by approx. 30 mm at the beginning and at the end.
2. Insert the windscreen into the body.
2.1. Affix suction cups to the windscreen and insert the windscreen into the window aperture. Fit the windscreen at the upper edge and position the lower rim.
3. Adjust gap for windscreen. -> 641219 Removing and installing windscreen - section on "Adjusting"
3.1. Slide the windscreen up against the filler piece.
3.2. Connect side of windscreen to window aperture.
Information
- Only if the windscreen is re-installed
3.3. Secure the windscreen with adhesive tape -1- to prevent it from slipping.
Securing the windscreen
Information
- Only with new windscreens
3.4. Pull off backing paper -1- on the adhesive strip at the lower edge and press the windscreen on.
Fixing windscreen in place
4. Adhesive that has oozed out must be removed immediately and the affected fields of vision must be cleaned using cleaning agent.
5. Secure the roof trim panel.
5.1. Move roof trim panel up into installation position -B-.
Securing roof trim panel
5.2. Clip in roof trim panel close to the sliding roof cut-out. (Only on vehicles with a sunroof)
5.3. Screw in fastening screws -1- => Tightening torque: 5.5 Nm (4 ftlb.) for the front roof trim panel -A-.
6. Screw in fastening screws -1- => Tightening torque: 5.5 Nm (4 ftlb.) for the sun visor.
Securing sun visor
7. Clip in cap for sun visor base.
Clipping cap into place
8. Position holder for sun visor.
Installing holder
9. Screw in fastening screw -1- => Tightening torque: 5.5 Nm (4 ftlb.).
10. Close the cover until it engages securely.
Closing cover
11. Swivel sun visor into place -B- and clip it in -A-.
Swivelling in sun visor
Subsequent work
1. Install cowl panel cover. -> 508719 Removing and installing cowl panel cover - section on "Installing" Service and Repair
2. Install roof joint cover strips at the left and right. -> 663619 Removing and installing roof joint cover strip - section on "Removing" 663619 Removing and installing roof joint cover strip
3. For vehicles with a rain sensor - Install rain sensor. -> 921219 Removing and installing rain sensor - section on "Removing" Service and Repair
4. On vehicles with a telephone: Install antenna for telephone. -> 919019 Removing and installing control unit for telephone - section on "Removing" 919019 Removing and installing control unit for telephone
5. Install interior rear-view mirror. -> 682719 Removing and installing interior rear-view mirror - section on "Removing" 682719 Removing and installing interior rear-view mirror
6. Install A-pillar trim panel at the left and right. -> 705719 Removing and installing A-pillar trim panel - section on "Removing" 705719 Removing and installing A-pillar trim