Operation CHARM: Car repair manuals for everyone.
Manuals through 2025 now available!

Our trusted friends have launched a new website named LEMON, which has newer manuals. It also contains all the CHARM manuals.

LEMON is the spiritual successor to CHARM, I recommend you try it!

Link: lemon-manuals.la or lemon-manuals.org.ua

(Some people have issue connecting. LEMON is investigating. For now, use Firefox or change your DNS server)

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Assembly Overview



Assembly Overview







1 - Windshield
- Distance to roof dimension - a - = 6 mm ± 0.5 mm
- Align distance - d - at sides.

NOTE: Stickers on windshield (e.g. for airbag) must be replaced in same position on new windshield.

2 - Adhesive bead
- Observe curing times
- Note varying spacing dimensions to window edge.
- Distances of top and side window edge dimension - b - and dimension - d - = 4 mm
- Distance at lower window edge measured from inner side of clip dimension - c - = 10 mm.
- Bead cross section
- Bead width = 8 ± 2 mm
- Bead height = 13.5 ± 1.5 mm
3 - Spacers
- 5x
- Affix in regular intervals to retaining strip
4 - Protective piping
- Only installed as new part.
- Only remove after installing windshield and before installing plenum chamber cover
5 - Plenum chamber cover
- Pull protective piping - 4 - from retaining strip before installing plenum chamber cover.
- Press into fastening strip only after window adhesive curing time has elapsed.