Glass, Window Regulators: Other Volkswagen Golf Mk7

MATERIALS

MINIMUM CURING TIME

The minimum curing time for 2K adhesive is 2 hours for all 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 15 °C) (59 °F).

Scheme 5

1. Rear Window Removing rear window, refer to «UNDAMAGED REAR WINDOW, REMOVING»(ref-480953-S30746108862012061900000) .
2. PUR Adhesive Sealant Bead diameter: width = 6.5 mm -dimension b- height = 10 mm -dimension a- (including pre-coating, residual material on window glass and window flange). Apply the bead of adhesive on the side edge of the window glass. Minimum curing time, refer to «MINIMUM CURING TIME»(ref-480953-S00378535822012061900000) .
3. Body Flange
4. Spacer
5. Window Defrosting Connector
6. Antenna Connectors

Scheme 6

1. Side Window Remove side window, refer to «UNDAMAGED SIDE WINDOW, REMOVING»(ref-480953-S33915893572012061900000) . Installing side window, refer to «SIDE WINDOW, INSTALLING»(ref-480953-S28758840152012061900000) .
2. Seal Component part of side window.
3. PUR Adhesive Sealant Bead diameter: width = 6.5 mm -dimension a- height = 10 mm -dimension b- (including pre-coating, residual material on window glass and window flange). Minimum curing time, refer to «MINIMUM CURING TIME»(ref-480953-S00378535822012061900000) .
4. Body Flange
5. Upper Gap Dimension 5.5 mm remaining the same.
6. Rear Gap Dimension Remaining the same, no visible gap between the seal and the side panel.
7. Adhesive Bead End Apply the adhesive bead in this area.

Scheme 7

1. Windshield Removing windshield, refer to «WINDSHIELD»(ref-480953-S10521764032012061900000) .
2. PUR Adhesive Sealant Bead diameter: width = 6.5 mm, height = 10 mm (including pre-coating, residual material on window glass and window flange). Minimum curing time, refer to «MINIMUM CURING TIME»(ref-480953-S00378535822012061900000) .
3. Body Flange
4. Drip Rail Removing and installing, refer to «DRIP RAIL»(ref-480927-S29860565392012061900000) .
5. Gap Dimension From window edge to roof edge. Set a constant dimension of 2.5 mm using adjustment gauge 3371.
6. Sealing Lip Is a part of the windshield. It will get damaged when removing the windshield. Install a new sealing lip.
7. Interior Rearview Mirror
8. Window Adjuster 443.845.631 A
9. Retainer Is a part of the windshield
10. Plenum Chamber Cover Must only be pulled out of binding profile by hand.
11. Adhesive Bead End Apply the adhesive bead in this area.

UNDAMAGED WINDOW, PREPARING FOR GLAZING

Adhesive Bead, Cutting

Note. When using an undamaged window again, cut back remaining adhesive sealant to 12 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.

Exception: If bonding is not performed immediately after cutting back, the remaining material must be activated using the activator D 181 801 A1.

New Sealing Lip, Installing

Special tools and workshop equipment required

Scheme 8

1. Gauge T10391

Note. The narrow seam on the windshield can damage the sealing lip when removing it. Install a new sealing lip if an undamaged window is going to be reinstalled. Make sure the adhesive surfaces are free of dust and grease. Only use adhesive remover D 002 000 10. Apply the sealing lip immediately after cleaning. Peel off the protective film just before installing. Temperature approximately. 21 °C (70 °F).

Scheme 9

Remove the damaged sealing lip.

Remove completely any left over adhesive.

Clean the ceramic surface with adhesive remover.

Set the T10391 to 6 mm -dimension a-.

Mark the inner dimension of the sealing lip -3- over the entire width with a ball-point pen and the -2- and the gauge.

Apply the new sealing lip on the line.

PREPARING NEW WINDOW WITHOUT PRE-COATING FOR GLAZING

All windows as replacement parts are not pre-coated.

Note. The application area for adhesive bead 3 is not pre-coated and not primed. The sealing lip is part of a new windshield.

Clean window circumference to width of 20 mm all around using cleaning solution.

Then dry the edge of the window with a lint-free cloth.

Apply primer -2- uniformly in one stroke using applicator -1-.

Scheme 10

1. Drying time is approximately 10 minutes

WINDOW FLANGE, PREPARING FOR GLAZING

Special tools and workshop equipment required

1. U-shape knife V.A.G 1561/3

All Body Flanges

Cut back remaining material on body flange using V.A.G 1561/3, do not remove all residue under any circumstances.

Scheme 11

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

Exception: If bonding is not performed immediately after cutting back, the remaining material must be activated using the activator.

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

Windshield Body Flange

Note. It is possible that the laser weld seam does not lie in the area of the adhesive bead. In this case, the open weld seam must be sealed with window adhesive before bonding the window.

If the laser weld seam -3- on the sheet metal flange -4- is not covered by the adhesive bead -1-, then coat the laser weld seam -3- with glass/paint primer -3- and fill the weld seam with window adhesive -1-.

Scheme 12

Rear Window Body Flange

Note. If the adhesive tape is damaged when removing the rear window, new adhesive tape must be reapplied. If no adhesive tape is applied, rainwater from the rear lid will drip into the luggage compartment.

Scheme 13

1. Rear Lid
2. Adhesive Tape -- Apply the left and right adhesive tape1K6.827.972 in the indicated positions.
3. Rear Window

ADHESIVE SEALANT, REMOVING FROM WINDOW

It is recommended to use adhesive remover D 002 000 10 as a cleaning solution. Follow the safety precautions when using it.

First clean paint surface coarsely using a dry rag. Eliminate remaining soiling using adhesive removal solution D 002 000 10.

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

BROKEN SIDE WINDOW, REMOVING

The procedure for removing a broken side window is identical to removing a broken rear window. Refer to DAMAGED REAR WINDOW, REMOVING

DAMAGED REAR WINDOW, REMOVING

Protect body and interior from glass splinters.

Remove glass pieces from adhesive material.

Remove harness connectors for glass defroster and antenna.

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

Scheme 14

Cut through adhesive material (with glass residue) in window opening using V.A.G 1561 A and knife V.A.G 1561.

REAR WINDOW, INSTALLING

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

Window, New, Preparing for Glazing. Refer to PREPARING NEW WINDOW WITHOUT PRE-COATING FOR GLAZING

Window Flange, Preparing for Glazing. Refer to WINDOW FLANGE, PREPARING FOR GLAZING

Installation Information. Refer to INSTALLATION INFORMATION

Minimum curing time. Refer to MINIMUM CURING TIME

SIDE WINDOW, INSTALLING

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

Window, New, Preparing for Glazing. Refer to PREPARING NEW WINDOW WITHOUT PRE-COATING FOR GLAZING

Window Flange, Preparing for Glazing. Refer to WINDOW FLANGE, PREPARING FOR GLAZING

Installation Information. Refer to INSTALLATION INFORMATION

Minimum curing time. Refer to MINIMUM CURING TIME

UNDAMAGED REAR WINDOW, REMOVING

Note. If windshield is to be used again, make sure that electrical connections for windshield heating are not damaged.

Scheme 15

Remove the rear lid trim panel and the window frame trim panel. Refer to Removal and Installation

Disconnect the right and left connectors for the heated rear window and tape them to the window glass.

Depending on the vehicle equipment level, disconnect the antenna connections and tape them to the window glass

Thrust V.A.G 1474/2 -1- through adhesive bead.

Scheme 16

Pull the cutting wire -2- inside through adhesive using V.A.G 1474/2 -1-.

Secure end of cutting cord -3- with handle -1- V.A.G 1351/1 before pulling out.

Scheme 17

Lay cutting cord -3- around the window and also guide inside the second cord end.

Secure end of cutting cord to V.A.G 1654 A -2-.

Mount the V.A.G 1654 A -2- as illustrated.

Relocate V.A.G 1654 A -2- appropriately and cut window free.

While cutting free, press cutting cord -3- against window using V.A.G 1474/5 to have clearance to window flange.

UNDAMAGED SIDE WINDOW, REMOVING

Note. The following describes removing and installing the left side window. Removing and installing the right side window is identical.

Remove the side trim panel. Refer to Removal and Installation

Scheme 18

Pull cutting cord -1- through adhesive sealant at place shown in picture into vehicle interior at lower area of rear window using V.A.G 1474/2 from V.A.G 1474 A.

Insert the cutting cord -3- into the window flange behind the seal using the small tube -1-.

Scheme 19

Secure a cord end -3- to V.A.G 1351/1 -2- to counter hold.

Scheme 20

Pull other end -2- of cutting cord into interior.

Secure other end of cord to V.A.G 1654 A -3-.

Cut window free by moving V.A.G 1654 A -3- accordingly.

While cutting window free, push cutting cord with plastic wedge against window in order to have clearance at window flange.

V.A.G 1654 A -3- can be used in place of V.A.G 1654 -3

Scheme 21

As shown in illustration, one suction cup can be removed from the V.A.G 1654 -3-. By doing this, the roller on the V.A.G 1654 A -3- can be placed closer to the window flange.

WINDSHIELD

Removing

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

Remove the sun visors. Refer to Removal and Installation .

Remove interior rearview mirror. Refer to Removal and Installation .

Remove the headliner. Refer to Removal and Installation

The headliner can now be lowered far enough so that windshield can be cut out without damaging headliner.

On vehicles with a rain sensor, refer to [For transmission(s) 0A4, 02E, 09G, 02Q] [For engine(s) CBTA, CJAA, CBUA, CCTA, CBFA] Removal and Installation

Remove plenum chamber cover. Refer to PLENUM CHAMBER COVER .

Push the V.A.G 1474/8 -1- in between the windshield and instrument panel.

Scheme 22

Pull the cutting wire -2- with the V.A.G 1474/2 through the adhesive inside the passenger compartment.

Secure cutting cord end on the inside against pulling out using V.A.G 1351/1 -3-.

Scheme 23

Insert cutting cord -2- into window flange by aid of small tube -1-.

Lay cutting cord around window.

Make sure the cutting cord is inserted under the corners of the windshield.

Secure second cutting cord end onto V.A.G 1654 A.

Scheme 24

Set V.A.G 1654 A to "position I".

Relocate V.A.G 1654 A appropriately and cut window free.

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

Installing

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

Window, New, Preparing for Glazing. Refer to PREPARING NEW WINDOW WITHOUT PRE-COATING FOR GLAZING

Window Flange, Preparing for Glazing. Refer to WINDOW FLANGE, PREPARING FOR GLAZING

Installation Information. Refer to INSTALLATION INFORMATION

Minimum curing time. Refer to MINIMUM CURING TIME

FRONT DOOR WINDOW

Removing

Note. The following describes removing and installing the right door window. Removing and installing the left door window is identical. Bolts -3- have a left-hand thread.

Scheme 25

Remove front door trim. Refer to Removal and Installation .

Pry out cover caps -6-.

Lower the door window -2- until the clamping screws -3- are accessible.

Loosen bolts -3- (do not remove. left-hand thread) and press clamping brackets apart.

Note. If this cannot be done because of a power window malfunction, remove the window regulator motor and then slide the window down.

Scheme 26

Lift the rear door window -1- and remove it in -direction of arrow- from the window guides -2-.

Installation

Note. The following describes removing and installing the right door window. Removing and installing the left door window is identical.

Scheme 27

Install the door window -1- in -direction of arrow a- into the window guides. Make sure the door window sits correctly inside the window guide.

Without using any pressure, guide the door window -arrow b- into the clamping brackets -3-.

Align the door window with the window frame -arrow c-.

Tighten clamping screws -3- (quantity: 2 left-hand thread), tightening specification: 8 Nm.

Note. Bolts -3- have a left-hand thread.

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

1. A function test must be performed before door trim is installed.

FRONT DOOR WINDOW REGULATOR MOTOR

Removing

Scheme 28

Remove front door trim. Refer to Removal and Installation .

Fix window using adhesive tape so that it does not slip down.

Disconnect the connector -3-.

Remove the three bolts -2-.

Remove window regulator motor with control module -1- from subframe.

Installation

Install the window regulator motor -1- and pull door window up and down so that splines are located better between motor and cable drum.

Tightening specification for the bolts -2- : 3.5 Nm

Connect the connectors -3-.

Code the new window regulator motor using the VAS 5051 A.

After coding, let the window regulator work in the one-touch up/one-touch down mode and pull the switch for 2 seconds. This way the window regulator recognizes it upper stop.

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

FRONT DOOR WINDOW GUIDE

Note. The following describes removing and installing the right window guide only. Removing and installing the left window guide is identical. Do not bend window recess seal when lifting off!

Removing

Scheme 29

The exterior mirror, the window shaft strip and the trim have been removed.

Remove the window guide -1- out of the mounts -3 and 4- -arrows a and b-.

From the inside, fold back the sealing lip on the window guide -1- from the window frame -arrow d-.

Starting the rear, pull the window guide -1- evenly -arrows c- off the door flange -2-.

Installation

To install, perform the steps used for removal in reverse order.

1. A function test must be performed before door trim is installed.

Note. While installing window guide, make sure it is seated evenly (wind noise).

REAR DOOR WINDOW

Note. The following describes removing and installing the right rear door window. Removing and installing the left rear door window is identical.

Removing

Scheme 30

Remove rear door trim. Refer to Removal and Installation .

Remove cover cap -5-.

Lower door window until spreader pin -4- and spreader plug -3- are accessible in window regulator cut-out.

Note. If the work step is not possible due to a malfunction via the electrical window regulator, window regulator motor can be unscrewed -8- to be able to slide window down.

Install a 5 mm bolt (approximately 70 mm long) into the spreader pin -4- and pull bolt out of spreader plug -3-.

Screw a 8 mm bolt (approximately. 80 mm long) into spreader plug -3-.

Note. When screwing the bolt into spreader plug, do not use excessive force on the plug otherwise it may fall inside into the door.

Pull the spreader plug -3- out of the window guide -1- and out of door window.

Remove the trim. Refer to TRIM

Scheme 31

Remove the door window -1- upward and at an angle -arrows- from the window shaft strip -2-.

Installing

Note. Spreader plug and spreader pin must always be replaced when performing assembly work on door window. Before inserting spreader plug -3- and spreader pin -4-, check window -3- for damage.

Scheme 32

Center the spreader plug -3- and insert spreader plug with window -3- removed.

Press spreader pin -4- flush into spreader plug -3-.

Install the door window -1- into the door -2- and insert the door window into the slot in the window regulator guide -5-.

Using a light pressure from above -arrow a-, engage window -1- into window regulator -5-.

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

1. A function test must be performed before door trim is installed.

REAR DOOR WINDOW REGULATOR MOTOR

Note. Removing and installing the right window regulator motor is described here. Removing and installing the left window regulator motor is identical.

Removing

Scheme 33

Remove door trim. Refer to Removal and Installation

Fix window using adhesive tape so that it does not slip down.

Remove the three bolts -2-.

Disconnect the connector -3-.

Remove window regulator motor with control module -1- from subframe.

Installation

Install the window regulator motor -1- and pull door window up and down so that splines are located better between motor and cable drum.

Connect the connectors -3-.

Tightening specification for the bolts -2- : 3.5 Nm

Code a new window regulator motor with Vehicle diagnostic tester.

After coding, let the window regulator work in the one-touch up/one-touch down mode and pull the switch for 2 seconds. This way the window regulator recognizes it upper stop.

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

Scheme 34

Removing

Compress the locking ring -2- -arrows a-.

Pull the locking ring -2- just a little under the window crank -1- -arrow b-.

Remove the window crank -1- -arrow c-.

Installation

Slide back the locking ring -2-.

Install the window crank -1-.

REAR DOOR WINDOW GUIDE

Note. The illustration shows a right door hinge. The left door hinge is identical. Do not bend window guide when removing!

Removing

Scheme 35

From the inside, fold back the seal on the window guide -1- from the window frame -arrow d-.

Remove the window guide -3- from the mounts -arrows b-.

Remove both seal clips -4- -2- from the door.

Remove the seal -2- evenly -arrows a- from the door flange.

Remove the window guide evenly -arrows c- from the door flange.

Start with the fixed door window -6-.

Installation

Scheme 36

To install, perform the steps used for removal in reverse order.

Install the window guide -1- evenly on the door flange -arrows a-.

Install the seal -2- evenly on the door flange -arrows c-.

Install the clips -4-.

Install the window guide into the mounts -arrows b-.

Note. While installing window guide, make sure it is seated evenly (wind noise). The window guide -2- must touch the outer door seal -5-.

REAR DOOR FIXED DOOR WINDOW

Removing

Scheme 37

Remove door trim. Refer to Removal and Installation

Remove the window shaft strip. Refer to OUTER WINDOW RECESS SEAL

Remove the window guide. Refer to REAR DOOR WINDOW GUIDE

Pry out cover caps -4-.

Remove the bolts -5-.

Fold back the seal -2- from the flange.

Insert the T10236 under both clips -7-.

Push the door window -1- slightly out -arrow a- until the clips -7- are pushed out of the door -3-.

Remove the door window -1- and the bar -6- -arrow b- from the door -3-.

Installation

Scheme 38

Install the door window -1- into the door -arrow a-.

Push the door window onto the door -5- until the clips -6- audibly latch -arrows b-.

Tighten bolts -4-, tightening specification: 8 Nm.

Fold back the seal -2- around the flange.