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"
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. -> 914719 Removing and installing radio antenna - section on "Removing" Service and Repair
4. Remove cowl panel cover. -> 664419 Removing and installing cowl panel cover - section on "Removing" Service and Repair
5. 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
6. Remove sun visors. -> 682319 Removing and installing sun visor - section on "Removing" Removal and Replacement
7. Detach headliner at the front. -> 708419 Removing and installing headliner - section on "Removing" Service and Repair
8. Remove moulding for windscreen. -> 666119 Removing and installing moulding for windscreen - section on "Removing" Service and Repair
Technical values
Gap dimensions of windscreen
=> Gap dimension: 2.6 mm+/-0.5 mm
Windscreen to roof
=> Gap dimension: 2.4 mm+1 mm
Windscreen to roof
Removing windscreen
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.
1. Separate windscreen.
1.1. Remove windscreen with the cutting-wire separating device.
Information
- The procedure for removing car windows is described in -> 6X00IN General information on removing car windows.
Removing windscreen
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
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.
Removing adhesive residue
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.
Applying activator
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 windscreen with cleaning solution -H1-.
1.2. Apply primer -H2- to the glass flange in the area of 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
- Only with new windscreens
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. Apply adhesive to the windscreen.
Applying adhesive
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-.
3. Insert the windscreen into the body.
3.1. Affix suction cups to the window.
3.2. Guide the windscreen into the window aperture.
3.3. Slide the windscreen up against the seal.
3.4. Insert the windscreen at the sides of the window aperture and lower it (do not press at the sides).
3.5. Press the bottom of the windscreen onto the body as far as the guide stop.
3.6. Adjust gap for windscreen with respect to the roof. -> 641219 Removing and installing windscreen - Refer to Specifications
Information
- Only if the windscreen is re-installed
3.7. Secure the windscreen with adhesive tape -1- to prevent it from slipping.
Securing the windscreen
4. Adhesive that has oozed out must be removed immediately and the affected fields of vision must be cleaned using cleaning agent.
Removing emerging adhesive
Subsequent work
1. Secure headliner at the front. -> 708419 Removing and installing headliner - section on "Installing" Service and Repair
2. Install sun visor. -> 682319 Removing and installing sun visor - section on "Installing" Removal and Replacement
3. Install cowl panel cover. -> 664419 Removing and installing cowl panel cover - section on "Installing" Service and Repair
4. For vehicles with a rain sensor - Install rain sensor. -> 921219 Removing and installing rain sensor - section on "Installing" Service and Repair
5. On vehicles with a telephone: Install antenna for telephone. -> 914719 Removing and installing radio antenna - section on "Installing" Service and Repair
6. Install interior rear-view mirror. -> 682719 Removing and installing interior rear-view mirror - section on "Installing"
7. Install A-pillar trim panel at the left and right. -> 705719 Removing and installing A-pillar trim panel - section on "Installing" 705719 Removing and installing A-pillar trim
8. Install moulding for windscreen. -> 666119 Removing and installing moulding for windscreen - section on "Installing" Service and Repair