Back Window Glass: Service and Repair
WM 648619 Removing and installing rear window
Technical values
Preliminary work
1. Remove trim panel for tailgate. -> 709219 Removing and installing trim panel for tailgate - section on "Removing" Service and Repair
2. Remove wiper motor for rear window wiper system. -> 923419 Removing and installing wiper motor for rear window wiper system - section on "Removing" 923419 Removing and installing wiper motor for rear window wiper system
3. Remove rear spoiler. -> 665819 Removing and installing rear spoiler - section on "Removing" 665819 Removing and installing rear spoiler
Technical values
Gap dimensions of rear window
=> Gap dimension: 4.5 mm+/-0.8 mm
Rear window to side panel
=> Gap dimension: 2 mm+/-0.8 mm
Rear window to side panel
=> Gap dimension: 1 mm+/-0.8 mm
Rear window to side panel
=> Gap dimension: 4.5 mm+/-0.8 mm
Rear window to rear lid
=> Gap dimension: 3 mm+/-0.5 mm
Rear window to rear lid
=> Gap dimension: 2 mm+/-0.5 mm
Rear window to rear lid
Removing rear window
Information
- Make sure not to damage the heated rear window connections when removing the glass with the cutting wire.
- Cut up to just before the connection.
- Slacken the cutting wire.
- Guide the cutting wire past the connection on the inside.
Guiding cutting wire past electric connection
- Counter with an awl.
Countering with an awl
- Make sure that the cutting wire does not press against the electric connection when separating the glass.
- Continue separating the window glass.
1. Remove rubber sleeve from the wiper arm.
2. Release and disconnect electric plug connections for antenna amplifier control unit. -> 918619 Removing and installing control unit for antenna amplifier - section on "Removing" Service and Repair
3. Release and disconnect electric plug connections on antenna amplifier. -> 918419 Removing and installing antenna amplifier - section on "Removing" Service and Repair
4. Disconnect electric plug connections for rear window heating. -> 972719 Removing and installing wire harness for tailgate - section on "Removing" 972719 Removing and installing wire harness for tailgate
5. Release and disconnect electric plug connections on actuating cylinders for the rear lid. -> 557319 Removing and installing actuating cylinder for rear lid - section on "Removing" 557319 Removing and Installing Actuating Cylinder for Rear Lid
6. Fix plug connections for the antenna amplifier control unit and antenna amplifier in place on the rear window using adhesive tape.
7. Affix adhesive tape -1- to the top right corner of the rear window at the rear lid.
Position of adhesive tape
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.
8. Apply a bead of adhesive from inside out in the area protected by the adhesive tape using the scratch awl.
Information
- The procedure for removing car windows is described in => Removing glass with cutting wire separator.
9. Remove rear window with the cutting-wire separating device.
Removing window with cutting-wire separating device
Preparing window aperture for installation
Preparing window aperture for re-installation
1. Remove adhesive on the body.
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.
1.1. When removing remaining adhesive with a cutter -C- and flashing knife -D- on the body, ensure that a surface coating of adhesive remains.
Removing adhesive residue on rear lid
2. 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 coat 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.
Eliminating paint damage
Preparing rear window for installation
Preparing rear window for installation (re-installation only)
Information
- The removed rear window can be reinstalled if there was no prior damage to the rear window and the rear window was removed without damage.
Information
- Replace the seal at the bottom of the rear window.
1. Remove adhesive from the rear window.
Removing adhesive from rear window
1.1. Fit cutter -C- with the flashing knife -D- and remove remaining adhesive from the rear window, 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. Apply activator to the bonding section of the rear window.
2.1. During long idle periods, apply activator -H3- to the remaining adhesive.
Installing rear window
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
Information
- The removed rear window can be reinstalled if there was no prior damage to the rear window and the rear window was removed without damage.
Information
- Check stop bits.
- Replace damaged or missing stop bits.
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.
2. Apply adhesive to the rear window.
2.1. Using a bonding gun -A- , apply 2-component adhesive to the rear window along the precoating or on the primer in the form of a triangular bead measuring -X = approx. 15 mm-.
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.
Information
- Two persons are needed to insert, position and secure the rear window.
3. Close the rear lid and insert the rear window into the body.
Inserting rear window
3.1. Affix suction cups to the rear window.
3.2. Guide the rear window into the window aperture at the top.
3.3. Insert the rear window at the sides of the window aperture and lower it.
3.4. Press the rear window uniformly into the body.
3.5. Set gap dimension by moving the rear window. -> 648619 Removing and installing rear window - Refer to Specifications
3.6. Secure the rear window to the top of the rear lid with adhesive tape -1- to prevent it from slipping.
Securing rear window
4. Clean the fields of vision.
Removing adhesive compound
4.1. Adhesive that has oozed out must be removed immediately and the affected fields of vision must be cleaned using cleaning agent -H1-.
5. Fit rubber sleeve on the wiper arm.
6. Plug in and lock electric plug connections for antenna amplifier control unit. -> 918619 Removing and installing control unit for antenna amplifier - section on "Installing" Service and Repair
7. Plug in and lock electric plug connections on the antenna amplifier. -> 918419 Removing and installing antenna amplifier - section on "Installing" Service and Repair
8. Plug in electric plug connections for rear window heating. -> 972719 Removing and installing wire harness for tailgate - section on "Installing" 972719 Removing and installing wire harness for tailgate
9. Plug in and lock electric plug connections on actuating cylinders for the rear lid. -> 557319 Removing and installing actuating cylinder for rear lid - section on "Installing" 557319 Removing and Installing Actuating Cylinder for Rear Lid
Subsequent work
1. Install trim panel for tailgate. -> 709219 Removing and installing trim panel for tailgate - section on "Installing" Service and Repair
2. Install wiper motor for rear window wiper system. -> 923419 Removing and installing wiper motor for rear window wiper system - section on "Installing" 923419 Removing and installing wiper motor for rear window wiper system
3. Install rear spoiler. -> 665819 Removing and installing rear spoiler - section on "Installing" 665819 Removing and installing rear spoiler