Side Window
Flush-Bonded Windows
Side Window
1 - Side Window
• Note varying spacing dimensions of adhesive bead to window edge.
• When installing, set window first on side panel at bottom.
• Press in window up to lower stop - arrow - and into window cut-out.
• After curing time has elapsed, install roof trim molding and trim to - D - pillar.
2 - Roof Trim Molding D-pillar
• C-pillar trim removed.
• To remove, pry carefully out of clips beginning first at bottom on C-pillar.
• Then pry out of clips at - D - pillar and pull downward out of roof trim molding.
3 - C-pillar trim
• To remove, pull trim panel out of clips - 4 - toward rear.
• When installing, insert trim panel first at top on roof trim molding and press completely into clips - 4 -.
• Dimension a = 0.5 ± 0.1 mm
4 - Retaining Clips
• Riveted to C-pillar.
Undamaged Window, Removing
- Remove C-/D-pillar trim.
- Apply adhesive tape - 3 - to C- and D-pillars as well as side panel to protect paint from damage.
- Remove the trim molding - 1 - from the clips - 2 -.
CAUTION!
Roof trim molding must not be bent.
- Using the plastic trim wedge, carefully remove the roof trim molding - 1 - starting from the bottom of the C-pillar.
- Pry out roof trim molding at D-pillar in the same manner out of clips and pull off downward.
- Route the cutting cord around the side window as shown in the illustration.
- Secure ends X and Y in two pull grips from special tool (V.A.G 1351).
- Pull cutting cord in direction of - arrow A - using light sawing motions and cut through lower adhesive sealing material at side panel and at roof frame.
- Then pull cutting cord through in direction of - arrow B - downward through adhesive sealing material.
- Remove window from window opening.
Preparing for Window Installation
• If windshield flange was damaged during removal, paint structure should be repaired and if necessary, corrosion repair measures should be taken.
For Undamaged Removed Windshield
- When reusing an undamaged window, cut remaining adhesive sealing material on window and flange using a carpet knife so that it is even, but 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.
- Apply adhesive onto residual adhesive bead
• Bead width = 8 ± 2 mm
• Bead height = 13.5 ± 1.5 mm
• Adhesive sealing material DH 009 100 03 (small cartridge) is recommended when bonding a single window; D 004 300 05 (2K- adhesive) is recommended when bonding more than one window.
With New Window
- Clean windshield in adhesion area using D 009 401 04 and prime using D 009 200 02 glass/paint primer.
- Ensure an air drying time of 10 minutes for primer.
- Apply adhesive
Dimensions for Adhesive Application
1 Adhesive sealing material
2 Primer
3 Window
• Bead width - a - = 8 ± 2 mm
• Bead height = 13.5 ± 1.5 mm
• Dimension - c - = note varying spacing dimensions to window edge.
- Press the roof trim molding into the clips on the D-pillar.
- Press the trim - 1 - into the clips - 2 - on the D-pillar and at the bottom of the side panel.
- Position window at lower side panel and press into opening.
- Slide window onto stop at B-pillar.
- Secure window in opening using adhesive tape.
Adhesive Bead Spacing to Window Edge
1 - Side Window
• When installing, push the window up to stop - arrow - on window flange.
2 - Adhesive Sealing Material
• Distance - a - = 18.5 mm
• Distance - b - = 6.5 mm
• Distance - c - = 8 mm
- Position upper B-pillar trim at roof trim molding and slide trim - 1 - into side clips.
- Observe curing time.