WINDSHIELD
Removing
Remove windshield wiper arms. Refer to WINDSHIELD WIPER ARMS .
Remove the cowl panel trim. Refer to COWL PANEL TRIM .
Remove left, center and right sun visors. Refer to Removal and Installation .
Remove the interior rearview mirror. Refer to Removal and Installation .
Remove upper A-pillar trim on left and right. Refer to Removal and Installation .
| WARNING | When removing a window, always wear protective eyewear and leather gloves. |
From the VAS 6452/1, pull out approximately 6.5 meter of cutting wire (about 6 turns) and cut it.
Cover the awl outlet under the body flange with tape -1- to prevent damaging it.
Poke the awl through the bead of adhesive from the inside to the outside as illustrated.
Scheme 39
Feed both cutting wire ends -3- into the awl -2- and pull it in.
Place the cutting wire all the way around under the windshield as illustrated.
Scheme 40
| CAUTION | The ends of the wire must not be twisted when cutting through the adhesive -arrow-. |
Mount both spools on the inside of the windshield as illustrated.
Scheme 41
Insert the ends of the cutting wire -1- into the spool -2
Scheme 42
Tension the cutting wire and place the protective foil -2- between the instrument panel and the wire
Scheme 43
Cut the first section open, while doing this, the wire is guided into the integrated roller -arrow- on the spool
Scheme 44
Insert an additional guide awl -2- into the adhesive and secure it to the windshield with the suction cup as illustrated to make sure that the wire runs as close to the windshield as possible.
Scheme 45
If necessary, move the protective foil -3- along with the wire and cut the windshield free with the spool -1-.
Move the spool and the guide awl as illustrated and cut free the section along the A-pillar.
Scheme 46
Moved the spool and guide awl approximately to the center of the windshield.
Cut free the windshield up to about the center.
Scheme 47
Cut free the lower section of the windshield with the second spool
Scheme 48
Move the spool upward and insert the guide awl as illustrated.
Scheme 49
Cut free the windshield along the A-pillar upward.
Scheme 50
Move the spool over the center of the windshield as well as the first spool as illustrated and cut free the rest of the windshield along the top.
Scheme 51
Remove the windshield from the vehicle with the double suction cups.
Installing
Preparations for Installing the Windshield
When reusing the undamaged window, cut rest of adhesive material on window and flange with V.A.G 1561 A and V.A.G 1561/8 so it is even, but do not remove completely.
Note. 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. |
With New Window
Clean window all around in adhesive area using D 009 401 04.
Apply D 009 200 02 as described below.
| CAUTION | Ceramic application on window is not primer! It must be primed before the application of adhesive sealing material! |
Applying Primer
Scheme 52
Apply primer -3- with applicator -2- evenly in one stroke near the window molding -1- on the window -4-.
Beginning applying with saturated felt.
- Primer width approximately 20 mm.
- Apply primer in center of adhesive bead.
- Curing time 10 minutes
Window Flange
If the windshield flange was damaged, then it must be repainted and if necessary, corrosion protected.
First clean corrected area with D 009 401 04 and then apply D 009 200 02.
Windshield, Installing
Note. Cross-section thickness of adhesive bead is determined by dimension of opening in nozzle tip and rate of application.
Dimensions for adhesive application
Scheme 53
- Adhesive sealing material
- Primer
- Window
- Dimension -a- = 8 mm
- Dimension -b- = 12 mm
- Dimension -c- = note varying spacing dimensions to window edge (Scheme 56).
Position complete surface of nozzle -2- onto window.
Scheme 54
- Application direction -arrow- for adhesive bead -1-.
Apply adhesive sealing material -1- all around on window -2- according to illustration.
Scheme 55
With an undamaged removed window, apply adhesive to remaining bead.
Using double suction cups, install the windshield.
| CAUTION | The window must be installed within 15 minutes or the adhesive sealing material will not adhere properly. |
Center window along sides.
- Distance from the edge of the windshield to the roof frame. (Scheme 56)
- Secure the window to the top of the roof with adhesive tape.
Before installing plenum chamber cover, first remove protective profile -2- from clamping strip.
Scheme 56
- Windshield
- Adhesive Sealing Material Apply adhesive at distances to window edge listed below. Dimension -a- = 2 mm Dimension -b- = 18 mm Dimension -c- = 8 mm. Dimension -d- = 18 mm
- Plenum Chamber Cover Retaining strip can only be pressed in after minimum window adhesive curing time.
Center window along sides.
Note varying spacing dimensions to window edge
Press drip rail -1- into clips -2- until it stops only after curing time has elapsed.
Scheme 57
When pressing in drip rail, make sure sealing lip -arrow- lies flat against windshield and does not slip behind edge of windshield.
Scheme 58
Affix stickers on windshield (for example, for airbag) in same position on new windshield.
Determine dimensions -a- and -b- from adhesive on old window.
Adhesive can be applied wet, with distilled water.
Apply adhesive without bubbles and slide into correct position.
Blot excess water with paper.
Note. If windshield flange was damaged during removal, paint structure should be repaired and if necessary, corrosion repair measures should be taken.
Observe minimum curing time. Refer to MINIMUM CURING TIMES .