Procedure

Unbroken glass

Removing


CAUTION
Always wear protective goggles and leather gloves when removing and installing glass.


^ remove rear wiper arm

* 16 N-m (12 ft.lb.)

^ remove nut 1, cover 2
^ insert plastic wedge between sealing lip and window flange
^ using plastic wedge, loosen and separate sealing lip from flange
^ spray sealing lip with cleaning solution D 009 401 04

GL models

^ unclip left/right side trim next to window
^ pull off heated window glass electrical connector
^ remove high mounted brake light


CAUTION
Tape around window opening with cloth or fabric tape to prevent damage to paint when removing/installing glass

^ cut a 4.5 m (approximately 15 ft) of cutting wire





^ push in awl as shown
^ thread wire ends in and pull to inside





^ using homemade tube 1, push cutting wire between lip and window flange

Note
If slot is too narrow, push cutting wire from outside and press under lip with plastic wedge.

^ fasten outer wire end on wiper shaft, or pull wire end toward inside and hold with handle





^ tape under flange 3 side/top with cloth or duct tape
^ carefully locate and pull out wire ends
^ secure cutting wire to awl from VAG 1351
^ keep moving wire and progressively cut out glass

Broken glass


WARNING
Always wear protective goggles and leather gloves when removing and installing glass.


CAUTION
Part numbers are for reference only. Always check with your Parts Department for latest information.


CAUTION
Tape around window opening with cloth or fabric tape to prevent damage to paint when removing glass.


^ remove inner tailgate trim, see section 70
^ remove rear wiper arm
^ cover and protect interior/body from glass splinters
^ remove pieces of glass up to adhesive material
^ remove cap for window glass electrical connection
^ unclip left/right side trim next to window
^ pull off heated window glass electrical connector





^ tape flange 2 with textile or cloth tape
^ cut adhesive bead with commercial cutting tool

Installing


CAUTION
Do not remove adhesive completely. It is used as a base for new adhesive material.

If body flange at area of glass is being worked on or replaced, flange must be recleaned and primed after painting. Use paint primer D 009 200 02 or equivalent.

Ensure appropriate corrosion protection is applied as required.

Undamaged glass





^ cut remaining adhesive material 1 with cutter on body flange smooth.
* do not remove completely, leave 1-2 mm (3/64-5/64 in.) on flange
* do not damage coating and lip of spacer rib 2





^ do not damage spacer rib 1 and ceramic layer 2





^ continue to cut back remaining adhesive, as shown
* do not remove completely

^ apply cleaning solvent D 009 401 04 to body flange
^ before installing, clean prebonded seal with dry lint free cloth





^ apply thin coat of activator AMV 181 800 01 with applicator 4, D 009 500 25 to prebonded seal 5
* allow to dry for 10 minutes


CAUTION
Do not allow activator to come into contact with paint. Activator will damage paint finish.

Note
After adhesive is applied, glass must be installed within 15 minutes. Otherwise adhesive will start to harden.





^ apply adhesive around glass, at right angles onto prebonded seal 5
* apply adhesive to:

height = 11-13 mm (7/16-33/64 in.) (including
precoating on glass and flange)

width = 6-7 mm (15/64-9/32 in.)
* shape of adhesive bead is determined by
nozzle shape, as shown, and rate of application

^ reinstall and center glass
* press glass in up to upper guide frame and
flush to tailgate surface

^ secure tailgate glass in place with cloth tape until
adhesive is fully hardened
* approximately one hour