Glass, Window Regulators (Hatchback): Other Volkswagen Beetle A4

MATERIALS

Scheme 54

1. Windshield Windshield, Removing, refer to «WINDSHIELD, REMOVING, SEDAN»(ref-492842-S00991586882012080600000) Windshield, Installing, refer to «WINDSHIELD, INSTALLING»(ref-492842-S41231538312012080600000)
2. PUR adhesive sealant Bead diameter: width = 7 mm, height = 11 mm (including pre-coating, residual material on window glass and window flange) Minimum curing time, refer to «MINIMUM CURING TIME»(ref-492842-S28765947052012080600000)
3. Dimension -a- = 4 mm
4. Sealing lip (component part of pre-coating)
5. A-pillar
6. A-pillar trim
7. Window adjuster 443 845 631 A
8. Outer plenum chamber cover
9. PUR adhesive sealant joint Central within area of dimension -b- = 130 to 170 mm

Scheme 55

1. Side window Remove side window, refer to «UNDAMAGED SIDE WINDOW, REMOVING»(ref-492842-S02548628252012080600000) Installing side window, refer to «SIDE WINDOW, INSTALLING»(ref-492842-S41049040832012080600000)
2. Ceramic coating
3. PUR adhesive sealant Bead diameter: width = 7 mm, height = 11 mm (including pre-coating, residual material on window glass and window flange) Minimum curing time, refer to «MINIMUM CURING TIME»(ref-492842-S28765947052012080600000)
4. Sealing lip (component part of pre-coating)
5. Securing pin Quantity: 2 Cut off before removing window

MINIMUM CURING TIME

By using 2C-adhesive DA 004 600 A2, a shorter minimum curing time is achieved than the previously used adhesive.

Minimum curing time for the 2C-adhesive DA 004 600 A2 is uniformly 3 hours for all bonded windows!

Curing time means the time from when the window is bonded to when the vehicle is put back into use. During this time, the vehicle must stand on an even surface at room temperature (at least 60 °F (15 °C).

PAINT DAMAGE, REPAIRING

Paint structure must be re-established and if necessary, corrosion repair measures must be taken.

The following repair method is used for paint damage in areas that are not visible

Paint twice (wet on wet) using glass/paint primerD 009 200 02, minimum air drying time approx. 10 minutes.

Scheme 56

1. Rear window Rear Window, Removing, refer to «UNDAMAGED REAR WINDOW, REMOVING»(ref-492842-S24627654172012080600000) Rear Window, Installing, refer to «REAR WINDOW, INSTALLING»(ref-492842-S12642937572012080600000)
2. Ceramic coating
3. Dimension -a- = 4.5 mm
4. Sealing lip (component part of pre-coating)
5. PUR adhesive sealant Bead diameter: width = 7 mm, height = 11 mm (including pre-coating, residual material on window glass and window flange) Minimum curing time, refer to «MINIMUM CURING TIME»(ref-492842-S28765947052012080600000)
6. Trim
7. Contact for window heater

Scheme 57

1. Window guide Installed on the flange
2. Door window Removing, refer to «FRONT DOOR WINDOW»(ref-492842-S01708443932012080600000) Adjusting, refer to «DOOR WINDOW, ADJUSTING»(ref-492842-S09649970892012080600000)
3. Door
4. Outer window guide Installed on the flange
5. Window recess seal Installed on the flange
6. Trim
7. Phillips head bolt
8. Spring nut
9. Bolt 20 Nm
10. Window recess seal Installed on the flange
11. Subframe Removing and Installing, refer to «SUBFRAME»(ref-492842-S36651443662012080600000) The window regulator is a component of the subframe
12. Crank mechanism for mechanical window regulator Bolted on to subframe from rear
13. Window regulator motor Bolted on to subframe from front
14. Bolt 8 Nm
15. Cover
16. Bolt 10 Nm

DOOR WINDOW, ADJUSTING

Clamping brackets for door window must be in assembly holes.

Scheme 58

Press door window -1- into window guide -arrow- and tighten clamping brackets with bolts -2- (8 Nm).

Then perform function check.

ELECTRICAL COMFORT WINDOW REGULATOR (AUTOMATIC RUN-UP AND RUN-DOWN) WITH PINCH PROTECTION

With introduction of the comfort window regulator, the front window regulators are equipped in addition with automatic run-up and run-down functions.

Switch for automatic run-up and run-down for front windows are located in driver's door operating unit. Switches for driver and passenger door are equipped with a two-step function.

If the respective switch is pushed or pulled to the first step, the front window is opened or closed ("manually") as long as the switch is held or the respective end position is reached.

When the switch is pressed or pulled completely to the second step, the front window automatically opens or closes completely.

Additionally, the front passenger's door has a switch to operate the front passenger side window without two-step function.

All electrical window regulators are equipped with pinch protection. Window closing is automatically interrupted if obstructions block the closing route.

However, this does not apply when closing the windows from outside using the ignition key - in this case there is no pinch protection.

Window Regulator Function with Ignition Switched On, refer to WINDOW REGULATOR FUNCTION WITH IGNITION SWITCHED ON

Window Regulator Function with Ignition Switched Off, refer to WINDOW REGULATOR FUNCTION WITH IGNITION SWITCHED OFF

Establishing Automatic Run-Up and Run-Down, refer to ESTABLISHING AUTOMATIC RUN-UP AND RUN-DOWN

WINDOW REGULATOR FUNCTION WITH IGNITION SWITCHED ON

Open

Switch in driver's door

Press switch forward to the first step. Window is opened manually.

Press switch forward briefly to the second step. Window is opened automatically (automatic run-down).

Operate the switch again and the window stops.

Switch in front passenger's door

Press on lower surface of switch. Window is opened manually.

Close

Switch in driver's door

Pull switch forward to the first step. Window is closed manually.

Pull switch forward briefly to the second step. Window is closed automatically (automatic run-up).

Operate the switch again and the window stops.

Switch in front passenger's door

Press on upper surface of switch. Window is closed manually.

WINDOW REGULATOR FUNCTION WITH IGNITION SWITCHED OFF

The window regulators can still be operated approx. 10 minutes after switching ignition off, as long as the driver's or passenger's door is not opened.

When closing the front windows, there is no automatic closing function.

If the window in driver's or passenger's door is hindered by difficulty of movement or by an obstruction during closing sequence (force limitation), the window opens again immediately.

In this case the window can only be closed again when the ignition is switched on.

For vehicles with central locking system, the windows can be closed and opened also from outside. To do so, the key must only be held in the closing/opening position.

ESTABLISHING AUTOMATIC RUN-UP AND RUN-DOWN

Note. After disconnecting and connecting the vehicle battery, the automatic run-up and run-down of driver's and passenger's door is without function.

In order to restore this function after connecting the battery, proceed as follows

Lock vehicle from outside using driver's or front passenger's door.

When doing this, make sure that all doors and windows are completely closed.

Unlock vehicle and lock again via the driver's or passenger's door. While doing this, hold the key in lock position for at least one second.

The automatic run-up and run-down of the driver's and passenger's window is re-activated.

If there is a malfunction of the electrical window regulators, this is indicated by blinking of switch lights in driver's and passenger's door.

All lights in the door trim will flash for approx. 15 seconds after switching on the ignition.

OVERCOMING RESISTANCE IN PINCH PROTECTION

1. Requirement: Automatic run-up and run-down is OK.
2. Ignition switched on.

Close door window with window regulator switch (automatic run-up).

If a window is hindered by resistance or by an obstacle during closing sequence, the window opens again immediately (PP) has been activated).

After the window has opened, lift/press and hold switch of corresponding window again within 5 seconds.

If the window still cannot be closed by resistance or by an obstacle, the window immediately remains standing (PP has been activated).

After the window remains standing, the switch must be operated again within 5 seconds in order to close the window.

The window now closes over the obstruction without force limitation.

1. Ignition switched off.

If a window is hindered by resistance or by an obstacle during closing sequence, the window opens again immediately (PP) has been activated).

Operating window regulator switch from the inside has now been locked.

If ignition is switched on within 1 minute after opening the window and then the switch is pressed (close window), window is closed without automatic run-up.

WINDSHIELD, REMOVING, SEDAN

Remove A-pillar trim. Refer to Removal and Installation

If necessary, remove rain sensor. Refer to RAIN SENSOR .

Remove both sun visors.

Unhook sun visor -1- out of mount -2-.

Scheme 59

Pry the cap -6- out.

Remove the bolt -5-.

Remove sun visor mount -4- from mounting and disconnect harness connector -3-.

Pry off cap -7-.

Remove bolts -8- and remove mounts -2-.

Standard Interior Rearview Mirror

Scheme 60

Pull off rear edge of trim (with clock) -1- downward from roof trim and disengage trim at front edge.

Disconnect harness connector -2- for interior light (and clock).

Automatic Dimming Interior Rearview Mirror

Scheme 61

Pull trim (with clock) -1- against spring pressure toward rear -arrow A- and disengage trim at front edge -arrow B-.

Pull trim -1- downward at rear edge

Disconnect the connectors -2-.

Continuation for all vehicles

Scheme 62

Pull the interior rearview mirror -1- down at an angle to release it from the retaining plate -arrow- (retaining springs in mirror base).

Remove wiper arms (hex nuts M8 = 20 Nm).

Remove outer plenum chamber cover.

Remove sealing lip in upper area of windshield and along A-pillars from window flange using a plastic wedge, and spray with cleaning solutionD 009 401 04 (as a substitute for lubricant).

Using tube, insert cutting cord into window flange (cutting cable can also be used).

For very narrow gap dimensions, guide cutting cord from outside and press under lip using plastic wedge.

Push cutting cord end through adhesive sealant into vehicle interior using awl (from V.A.G 1474 A).

Scheme 63

Secure one end of the cord to the reel device V.A.G 1654.

Scheme 64

Pull through second cord inward and attach grip from V.A.G 1351 to counterhold.

Set spooling tool V.A.G 1654 into "Position I".

Move the reel device as needed and cut the windshield out.

While cutting free, press cutting cord against window using plastic wedge in order to have clearance from window flange and instrument cluster.

WINDSHIELD, INSTALLING

Preparing undamaged window for glazing. Refer to UNDAMAGED WINDOW, PREPARING FOR GLAZING .

Window, New, Preparing for Glazing. Refer to NEW WINDOW, PREPARING FOR GLAZING .

Preparing window flange for glazing. Refer to WINDOW FLANGE, PREPARING FOR GLAZING .

Installing, refer to INSTALLING .

Minimum curing time, refer to MINIMUM CURING TIME .

Install rain sensor.

RAIN SENSOR

Removing

Unclip rain sensor cover -1- using plastic wedge.

Scheme 65

Unhook clip -1- from retaining ring -2- and remove rain sensor -3- from windshield (light bonding).

Scheme 66

Disconnect the connector -4-.

Installation

When installing rain sensor after replacing windshield or rain sensor, the following must be observed

1. As a replacement part, windshields are supplied with retaining ring. After installing windshield, clean glass thoroughly in area of retaining ring using cleaning solutionD 009 401 04.
2. It is not possible to reuse rain sensor. Replacement is supplied with adhesive already applied for installation of rain sensor to windshield. Bonding can be used for only one installation.
3. To guarantee function of rain sensor, rain sensor must be bonded to windshield completely free of bubbles.

Remove protective cover for adhesive from new sensor.

Connect harness connector -4-.

Insert rain sensor -3- in retaining ring -2- and bond to windshield without bubbles.

Install clip -1-.

Install rain sensor cover -1-.

UNDAMAGED SIDE WINDOW, REMOVING

Remove side trim. Refer to Removal and Installation

Remove B-pillar trim. Refer to Removal and Installation .

Remove C-pillar trim. Refer to Removal and Installation

Cut through locating pins -1- using a knife before cutting sealant bead and remove from body.

Scheme 67

Insert plastic wedge between sealing lip and window flange.

Loosen sealing lip from window flange all around and spray in cleaning solutionD 009 401 04 (as a substitute for lubricant).

Push cutting cord through adhesive sealant into vehicle interior using awl (from V.A.G 1474).

Scheme 68

Note. When piercing adhesive bead, make sure that sealing lip -1- at window front edge is not also pierced.

Using tube -1-, guide in cutting cord between lip and window flange (if cutting cord breaks, a cutting cable can also be used).

Scheme 69

For very narrow gap dimensions, guide cutting cord from outside and press under lip using plastic wedge.

Place cutting cord around side window.

Secure one end of the cord to the V.A.G 1654.

Scheme 70

It is recommended to use V.A.G 1654 A instead of V.A.G 1654 because of shape and size of side window.

As shown in illustration, one suction cup can be removed from spooling tool. By doing this, the roller of the spooling tool can be placed closer to window flange.

Pull through second cord inward and attach grip from V.A.G 1351 to counterhold.

Move the reel device as needed and cut the windshield out.

While cutting, press the cutting cord against the window with a plastic wedge in order to have clearance from the window flange.

BROKEN SIDE WINDOW, REMOVING

Removal of damaged side window is similar to instructions for damaged rear window, refer to DAMAGED REAR WINDOW, REMOVING

SIDE WINDOW, INSTALLING

Preparing undamaged window for glazing, refer to UNDAMAGED WINDOW, PREPARING FOR GLAZING .

Window, New, Preparing for Glazing, refer to NEW WINDOW, PREPARING FOR GLAZING .

Preparing window flange for glazing, refer to WINDOW FLANGE, PREPARING FOR GLAZING .

Installing, refer to INSTALLING .

Minimum curing time, refer to MINIMUM CURING TIME .

UNDAMAGED REAR WINDOW, REMOVING

Note. It is not recommended to cut the window using an electric knife as the adhesive bead runs along the outer edge of the lid. Due to the width of the window flange, cutting is not possible especially at the top but also at the sides. When cutting from the outside, there is the danger of damaging the protruding sealing lip.

Remove rear lid trim. Refer to Removal and Installation

Disconnect harness connectors for heated rear window and press connector tabs onto window.

Loosen sealing lip at lower window edge from window flange using plastic wedge and spray in cleaning solutionD 009 401 04 (as a substitute for lubricant).

Push cutting cord through adhesive sealant in area of lid hinge to inside using awl (from V.A.G 1474).

Scheme 71

Note. When piercing adhesive bead, make sure that sealing lip -1- at window edge is not also pierced.

Lay cutting cord in window flange along lower edge of rear window using small tube.

For very narrow gap dimensions, guide cutting cord from outside and press under lip using plastic wedge.

Note. Press in cutting cord far enough to prevent damage to the lip/spacer.

Lay cutting cord -1- around window flange, engage above upper edges of lid and tighten.

Scheme 72

Due to the curve of the lid it is not possible to lay cutting cord at sides and upper edge into window flange.

Secure one cord end to spooling tool V.A.G 1654.

Scheme 73

In place of spooling tool V.A.G 1654, the spooling tool V.A.G 1654 A can also be used.

As shown in illustration, one suction cup can be removed from spooling tool. By doing this, the roller of the spooling tool in the radii can be placed closer to window flange.

Pull through second cord inward and attach grip from V.A.G 1351 to counterhold.

Set spooling tool V.A.G 1654 into "Position I".

Move the reel device as needed and cut the windshield out.

While cutting free, press cutting cord in direction of window using plastic wedge or awl (from V.A.G 1474) in order to have clearance at window flange.

Scheme 74

While cutting, cutting cord is pulled into window flange at sides and upper edge of window. If necessary, cutting cord must be guided or seating between lid and window must be corrected (wear leather gloves!).

DAMAGED REAR WINDOW, REMOVING

Protect body and interior from glass splinters.

Scheme 75

Remove glass pieces from adhesive material.

Remove harness connectors for glass defroster and antenna.

Bond flange -2- all around with fabric reinforced adhesive tape.

Cut through adhesive sealing material (with glass residue) from window opening using electric cutter and knife V.A.G 1561/10 (with stopper roll).

REAR WINDOW, INSTALLING

Preparing undamaged window for glazing, refer to UNDAMAGED WINDOW, PREPARING FOR GLAZING .

Window, New, Preparing for Glazing, refer to NEW WINDOW, PREPARING FOR GLAZING .

Preparing window flange for glazing, refer to WINDOW FLANGE, PREPARING FOR GLAZING .

Minimum curing time, refer to MINIMUM CURING TIME .

UNDAMAGED WINDOW, PREPARING FOR GLAZING

Note. When re-using an undamaged window, cut back remaining adhesive sealant to 1 to 2 mm shortly before re-adhering, do not damage primer and ceramic coating. The remaining material serves as a base for the new adhesive sealant being applied. Do not prime the adhesive surface or use a cleaning solution on it. Keep the adhesive surface free of dirt and grease. Exception: if the window is not bonded immediately after cutting back the adhesive, the remaining material must be activated with the activator D 181 801 A1.

NEW WINDOW, PREPARING FOR GLAZING

New windows are shipped pre-coated with -PUR-. Pre-coating consists of positions 1, 2 and 3.

Scheme 76

1. Sealing lip
2. Spacer
3. Application are for adhesive bead
4. Window

Rub pre-coating with a dry, lint-free rag.

Note. Do not prime or use a cleaning solution on the pre-coating.

Using applicator D 009 500 15 -1- (felt ball with wire), apply activator D 181 801 A1 thinly onto pre-coating -2- only.

Scheme 77

Allow activator to air dry for at least 10 minutes.

Note. The activator must not come into contact with the paint or the paint will be damaged.

WINDOW FLANGE, PREPARING FOR GLAZING

Cut back the remaining material using a scraper V.A.G 1561/8 but do not remove all of the residue.

Scheme 78

Note. The remaining material serves as a base for the new adhesive sealant being applied. Keep the adhesive surfaces free of dirt and grease.

Note. The activator must not come into contact with the paint or the paint will be damaged.

Exception: if the window is not bonded immediately after cutting back the adhesive, the remaining material must be activated with the activator D 181 801 A1.

1. If the window flange is being repair or partially replaced, the corresponding area must be clean and primed again before painting.

INSTALLING

Apply adhesive material all around onto pre-coating -1- at right angle to window.

Scheme 79

Note. The window must be installed within 10 minutes or the adhesive will not bond well.

1. Insert the window into the opening using two double suction lifters (VAG 1344). Center it and press it in as far as the spacer.
2. Attach side window from the front and rear window from above with protruding sealing lips.
3. Gap dimension of windshield, refer to «WINDSHIELD ASSEMBLY OVERVIEW»(ref-492842-S01401169272012080600000) .
4. Rear window gap dimension, refer to «REAR WINDOW ASSEMBLY OVERVIEW»(ref-492842-S14682536432012080600000) .
5. Secure the windshield with the window adjuster (443 845 631 A) while the adhesive cures.
6. Replace any stickers, such as the ones for the airbag.
7. Secure window glasses during curing time using adhesive tape.
8. If too much adhesive was applied and it spreads onto the window defroster, remove the excess.

ADHESIVE SEALANT, REMOVING FROM WINDOW

Using adhesive remover D 002 000 10 is recommended. Always follow the safety precautions when using adhesive remover.

Note. When cleaning from inside the vehicle, do not press out on the window that was just installed.

Clean the painted surface with a dry cloth. Clean off any dirt with adhesive remover D 002 000 10.

Clean the plastic trim: let the adhesive sealant harden for approximately 1 hour and then peel it off.

FRONT DOOR WINDOW

Remove front door trim. Refer to Removal and Installation

Pry the caps -1- out.

Scheme 80

Lower door window until bolts at clamping brackets are accessible.

Note. If work step is not possible due to malfunction of the electrical window regulator, window regulator motor can be removed to be able to slide window down.

Loosen bolts -2- and press clamping brackets apart.

Lower window regulator further.

Raise the rear door window and tilt it out of the door toward the front in the -direction of the arrow-.

Scheme 81

SUBFRAME

The window regulator, door lock and speaker are secured to the subframe.

The door lock can only be removed with the subframe.

Subframe can only be removed when the door window has been unscrewed at clamping brackets of window regulator. For this purpose, door window must be driven down to height of installation holes in subframe and clamping brackets loosened.

If it is not possible to drive down the door window by the electrical window regulator, first the exact cause of malfunction must be determined.

To do so, check DTC Memory of comfort system (address word 46) using Fault Read Out Device V.A.G 1551.

If electrical malfunction is present, repair this malfunction first.

If window regulator motor is cause for malfunction, proceed according to description LOWER DOOR WINDOW UNTIL SECURING BOLTS OF DOOR WINDOW ARE ACCESSIBLE. .

REMOVING

Remove front door trim. Refer to Removal and Installation

Remove lock cylinder housing.

Unclip the clip -1- from the door handle.

Scheme 82

Pry the caps -1- out.

LOWER DOOR WINDOW UNTIL SECURING BOLTS OF DOOR WINDOW ARE ACCESSIBLE.

Note. If work step is not possible due to malfunction of the electrical window regulator, window regulator motor can be removed to be able to slide window down.

Loosen bolts -2- and press clamping brackets apart.

Slide door windows upward and secure (for example, using adhesive tape).

Remove operating lever for front hood lock (driver side only). Refer to HOOD RELEASE LEVER .

Remove lower A-pillar trim. Refer to Removal and Installation

Disconnect multi-pin harness connectors -1- at A-pillar -2-.

Scheme 83

Remove cover -1- for wiring harness -2- out of body opening in inner A-pillar.

Scheme 84

Remove wiring harness at bellows -1- out of A-pillar between door and A-pillar.

Scheme 85

Disconnect the exterior rearview mirror connector -arrow- and unhook the wire at the subframe.

Scheme 86

Remove bolt -1- and unhook wiring harness guide -2- from door.

Guide wiring harness with bellows through door.

Remove bolts -1-. Tightening specification: 20 Nm.

Scheme 87

Remove bolts -1- to -11-. Remove the upper subframe from the door, raise it and lift it out toward the hinge side of the door.

Scheme 88

Rotate the subframe and disconnect the connector from the door lock.

Scheme 89

Pull lock lever -1- in -direction of arrow-.

Using a screwdriver, tension the spring -2- secured to the door lock in the direction of the arrow and engage the lock lever in the spring.

Note. Engaging the operating lever secures the lock. This prevents cable from being clipped in "incorrectly" later (lock may already be slightly loosened).

Insert the subframe into the door.

Attach all bolts -1- to -11-. Tighten bolts in order of numbering. Tightening specification: 8 Nm

Press door window -1- into window guide -arrow- and tighten clamping brackets with bolts -2- (8 Nm).

Continue by performing the steps used in removal in reverse order.

Then perform function test.

Identify upper position -A- and lower position -B

Scheme 90

Remove the old cable.

Install new cable. Start routing it at the white pulley and keep the black plastic cover pressed down along the cable route.

Scheme 91

Note. The cable must be installed as depicted in the illustration. The cable for the lower pulley must be installed first.

Install the upper left pulley as depicted in the illustration.

Scheme 92

Continue routing the cable in the third pulley (upper left position).

Scheme 93

For the last pulley (lower right position), install the cable in the holder and into the black plastic connector.

Scheme 94

Use the cable installation tool VWM 100 to install the cable through the pulley.

Scheme 95

Align the tool on the center point of the window guides.

Turn the tool 180° clockwise until the cable is installed in the pulley.

Scheme 96

Note. Make sure when turning that the cable is always in the guide

Check the window regulator to make sure it moves correctly.

Apply grease -G000045003- onto the guide rails, where the window regulator makes contact.

Remove the plastic strap and locking ring as shown in the illustration.

Scheme 97