Rear Window, Sedan
Rear Window, Sedan
Damaged Rear Window
Undamaged
Removing
• Always wear protective glasses and leather gloves when removing a window.
- Remove rear shelf.
- Remove or unscrew connectors for heated rear window and various window antennas.
- Press connections at window towards center of vehicle.
- Press awl through adhesive sealing material in lower window corner, until eye of awl is visible outside of vehicle.
- Thread beginning of cutting cord through eye and pull into vehicle interior.
- Thread cutting cord through spooling tool and clamp securely.
- Place cutting cord around window as shown.
- Cutting cord must be pressed under gap covers on upper window edge and side window edges.
- Lay end of cutting cord around buffer stop - arrow - and tighten with bolt for rear lid hinge.
- Cut first section.
- Move winding device as shown and attach relay pulley in lower window radius.
• Route cutting cord as shown.
- Cut adhesive up to point where cord no longer runs in relay pulley.
- Remove relay pulley and continue to cut adhesive.
- Move winding device as shown and attach relay pulley in lower window radius.
• Route cutting cord as shown.
- Cut adhesive up to point where cord no longer runs in relay pulley.
- Insert 1474/12 protective foil between molded headliner and rear window.
- Remove relay pulley and continue to cut adhesive.
- Repeat these steps in top right and bottom right corners of windshield.
- Cut glass completely free in this manner.
- Remove window using double suction cups.
Damaged Rear Window
Removing
CAUTION!
Always wear protective glasses and leather gloves when removing a window.
Protect body and interior from glass splinters.
- Remove glass pieces up to adhesive material.
- Disconnect connector - 1 - for antenna and amplifier.
- Remove harness connectors for glass defroster.
- Mask flange all around with fabric reinforced adhesive tape.
- Remove adhesive sealing material (with glass remnants) - 1 - in window opening using electric cutter (V.A.G 1561A) and knife (V.A.G 1561/11) (with stopper roll).
Preparing for Window Installation
• If windshield flange was damaged during removal, paint structure should be repaired according to specifications in Repair Information, "Vehicle-Paint " and if necessary, corrosion repair measures should be taken according to guidelines in "Surface Technology/Chemical Materials Folder".
- Observe different spacers for tinted glass and standard glass.
- Adhere lower spacer onto rear window according to the markings.
- Adhesive stopper profile - 2 - must be adhered onto left side, centered on antenna wire next to distributing wire for rear window heater.
- On the right side, adhere inner edge of profile onto outer edge of distributing wire for rear window heater.
• If adhesive sealing material leaks out at lower window edge during installation, this must be removed immediately.
CAUTION!
Window adhesive must not come into contact with the antenna wire or the distributing wire for rear window heater under any circumstances.
For undamaged removed windshield
- When reusing an undamaged window, cut back smoothly residual adhesive sealing material on window and flange using electric cutter (V.A.G 1561A) and scraper (V.A.G 1561/10); do not remove completely!
- Residual material acts as a base for the new adhesive sealing material.
CAUTION!
• 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.
New window, installing
- Clean windshield in adhering area using D 009 401 04 and prime using D 009 200 02 glass/paint primer.
Applying primer
- Apply primer - 2 - along circumference evenly and in one motion using applicator - 1 -.
- Begin application with a fully saturated felt. Air drying time approx. 10 minutes.
• Primer dimensions: Dimension - a - + approx. 20 mm
- Apply primer in center of adhesive bead.
CAUTION!
Ceramic application on window is not primer! It must be primed before the application of adhesive sealing material!
• Do not touch up primer strip until after primer has thoroughly dried.
Dimensions for application of adhesive
1 Adhesive bead
2 Primer
3 Washer
• Bead width - a - = 8 ± 2 mm
• Bead height - b - = 12 + 3 mm
• Dimension - c - = note varying spacing dimensions to window edge.
Installing
- After preparatory work has been performed, apply the adhesive.
- Position complete surface of nozzle - 2 - onto window.
- - Arrow - indicates direction of application
• Cross-section thickness of adhesive bead - 1 - is determined by dimension of opening in nozzle tip and rate of application.
- Apply adhesive sealing material all around, as shown in illustration.
- Note varying spacing dimensions to window edge.
- Using two double suction cups, install rear window in window opening.
CAUTION!
Window must be installed within 15 minutes, otherwise bonding properties of adhesive will be impaired.
- Align windshield at sides.
- Spacing between edge of window and roof frame must be 6.5 mm.
- Observe curing time.