Windshield, Removing and Installing
Windshield, Removing and Installing
Windshield, Removing
- Remove wiper arms.
- Remove the cowl panel trim. Refer to => [ Cowl Panel Trim ] .
- Remove the sun visors.
- Remove interior rearview mirror.
- Remove the rain/light recognition sensor (G397).
- Remove the left and right upper A-pillar trim.
When removing a window, always wear protective eye-wear and leather gloves.
- Disconnect all electrical wires to sensors and rearview mirror or to window heater.
- From the wire spool (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.
- 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.
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.
- Insert the ends of the cutting wire- 1 - into the spool - 2 -
- Tension the cutting wire and place the protective foil - 2 - between the instrument panel and the wire
- Cut the first section open, while doing this, the wire is guided into the integrated roller - arrow - on the spool
- 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.
- 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.
- Moved the spool and guide awl approximately to the center of the windshield.
- Cut free the windshield up to about the center.
- Cut free the lower section of the windshield with the second spool
- Move the spool upward and insert the guide awl as illustrated.
- Cut free the windshield along the A-pillar upward.
- 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.
- Remove the windshield from the vehicle with the double suction cups.
Preparations for Installing Windshield
- If the windshield flange was damaged, then it must be repainted and if necessary, corrosion protected.
- First clean corrected area with Cleaning Solution (D 009 401 04) and then apply Glass and Paint Primer (D 009 200 02).
- When reusing the undamaged window, cut rest of adhesive material on window and flange with Electric Cutter (V.A.G 1561 A) and Scraper (25 mm) (V.A.G 1561/8) so it is even, but do not remove completely.
• Residual material acts as a base for the new adhesive sealing material.
• 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 Cleaning Solution (D 009 401 04).
- Apply Glass and Paint Primer (D 009 200 02) as described below.
Ceramic application on window is not primer! It must be primed before the application of adhesive sealing material!
- 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
Windshield, Installing
• Cross-section thickness of adhesive bead is determined by dimension of opening in nozzle tip and rate of application.
Dimensions for adhesive application:
1. Adhesive sealing material
2. Primer
3. Window
• Dimension - a - = 8 mm
• Dimension - b - = 12 mm
• Dimension - c - = note varying spacing dimensions to window edge.
- Position complete surface of nozzle - 2 - onto window.
• Application direction - arrow - for adhesive bead - 1 -.
- Apply adhesive sealing material - 1 - all around on window - 2 - according to illustration.
- With an undamaged removed window, apply adhesive to remaining bead.
- Using double suction cups, install the windshield.
The window must be installed within 10 minutes or the adhesive sealing material will not adhere properly.
- Center window along sides.
• Secure the window to the top of the roof with adhesive tape.
- Before installing plenum chamber cover, first remove protective profile => [ Removing Protective Piping for Grip Channel ] Windshield Assembly Overview from clamping strip.
- Observe minimum curing time. Refer to => [ Minimum Curing Times ] Minimum Curing Times.
- Press drip rail - 1 - into clips - 2 - until it stops only after curing time has elapsed.
- When pressing in drip rail, make sure sealing lip - arrow - lies flat against windshield and does not slip behind edge of windshield.
"Caution - Safety Information" Label
- Affix stickers on windshield (for example, for airbag) in same position on new windshield.
- Adhesive can be applied wet, with distilled water.
- Apply adhesive without bubbles and slide into correct position.
- Blot excess water with paper.
• Dimension - a - = 25 mm
• Dimension - b - = 12 mm