64-1

Flush bonded windows

Tools
VAG 1474 A Cutting device for flush bonded windows VAG 1344 Suction lifter VAG 1351 Cutting tool VAG 1755 Window removal kit VAG 1628 Hand cartridge gun 3371 Adjustment gauge

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VAG 1561 A Electric cutter VAG 1561/8 Cutting blade VAG 1561/10 Cutting blade

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Materials
2K window adhesive Activator Glass primer/paint primer Cleaning solution Primer applicator Adhesive remover
1) 2)

D 004 300 05 2) AMV 181 800 02 1) D 009 200 02 1)

D 009 401 04 1) D 009 500 25 1) D 002 000 10 1)

Materials are stored in box D 004 700. Observe curing time Page 64-38 .

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Windshield, assembly overview

1 - Windshield Removing windshield Installing windshield 2 - PUR adhesive sealant Cross section of bead: Width 7 mm, Height 11 mm (including pre-coating, residual material on window glass and window flange) 3 - Dimension a 4 mm (0.16 in.) Page 64-6 Page 64-12

4 - Sealing lip (component part of pre-coating) 5 - Spacer (component part of pre-coating)

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6 - Roof molding 7 - Door 8 - Window adjuster Part No. 443 845 631 A 9 - PUR adhesive sealant joint

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Windshield, removing
- Remove wiper arms (M8 hex nuts). Tightening torque = 20 Nm (15 ft lb). - Pull roof molding strips off in area of A-pillar. - Remove A-pillar trim.

Repair Manual, Body Interior, Repair Group 70 - Release sun visor -1- from mount -2-. - Pry off cover -6-. - Remove bolt -5-. - Release sun visor mount -4- from mounting and separate connector -3-. - Pry off cover cap -7-. - Remove screws -8- and remove mount -2-.

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- Press interior rear-view mirror -1- downward at angle off retaining plate (spring clip in mirror base).

- Fold center sun visor -1- down (arrow). - Remove screw -2- from roof frame -3- and remove sun visor.

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Removing plenum cover - Unclip cover -1- from inner side of fender in area of hood hinge -2- on left and righthand sides.

- Remove rubber seal -1- completely and remove bolts -2-. - Remove pollen filter cover -3- in forward and upward direction.

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- Press plenum cover -1- upward (arrow) out of seat on windshield lower edge -2-.

- Lift up retaining tab -1- and pull hood hinge cover -2- inward (arrow) off hood hinge -3(left and right).

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- Slide protective foil -1- VAG 1474/8 between windshield and instrument panel. - Loosen sealing lip in upper area of windshield with a plastic wedge and spray in cleaning solution D 009 401 04 (as a substitute for lubricant). - Place cutting thread -2- in window flange with help of tube (cutting wire may also be used). If gap is too small guide cutting thread from outside and push under lip with a plastic wedge. - Pull cutting thread end through adhesive sealing material into vehicle interior using broach (from VAG 1474 A). Note: Guide the broach through the adhesive sealing material as close as possible to the body windshield flange, along the sides of the windshield, to prevent damage to sealing the lip.

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- Secure an end of thread to winding device VAG 1654. - Pull second thread end into vehicle and counter-hold with pulling handle from VAG 1351. - Place winding device VAG 1654 in "Position I". - Move winding device according to position required and cut windshield free. Note: Press cutting thread against window glass with plastic wedge during cutting process, in order to have clearance at window flange and instrument panel.

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Windshield, installing
Preparing old undamaged window for glazing Page 64-31 . Preparing new window for glazing 32 . Preparing body flange for glazing 35 . Installation instructions Curing time Page 64Page 64-

Page 64-36 .

Page 64-38 .

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Side window, assembly overview

1 - Side window Removing side window Installing side window 2 - Ceramic layer 3 - Sealing lip (component part of pre-coating) 4 - PUR adhesive sealant Cross section of bead: Width 7 mm; Height 11 mm (including pre-coating, residual material on window glass and window flange) 5 - Dimension a 5 to 6 mm (0.20 to 0.24 in.) Page 64-14 Page 64-16

The gap must be adhered to, because the dimension is required to secure the roof load system mountings

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Undamaged side window, removing

- Remove side trim.

Repair Manual, Body Interior, Repair Group 70 - Remove B-pillar trim.

Repair Manual, Body Interior, Repair Group 70 - Remove side support for luggage compartment cover and remove C-pillar trim.

Repair Manual, Body Interior, Repair Group 70 - Insert plastic wedge between sealing lip and window flange. - Loosen sealing lip from window flange all around and spray in cleaning solution D 009 401 04 (as a substitute for lubricant).

- Pull cutting thread through the adhesive sealing material into vehicle interior with broach (from VAG 1474).

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- Guide cutting thread in between lip and window flange with help of tube -1- (If cutting thread should break, then cutting wire can also be used). If gap is too small guide cutting thread on outside and press under lip with a plastic wedge. - Place cutting thread around side window.

- Secure outer end of thread to pull toggle from VAG 1351 to counter-hold. - Secure inner end of thread to winding device VAG 1654 and cut out window by moving winding device as necessary. Note: Press cutting thread against window glass with plastic wedge during cutting process, in order to have clearance at window flange.

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Broken side window, removing

The removal of a broken side window is very similar to the removal of a broken rear window Page 64-22 .

Side window, installing

Note: Information on the material used to pre-coat the side windows (2-door) can be found on page Page 64-32 . Preparing old undamaged window for glazing Page 64-31 . Preparing new window for glazing 32 . Preparing body flange for glazing 35 . Installation instructions Curing time Page 64Page 64-

Page 64-36 .

Page 64-38 .

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Rear window, assembly overview (Golf)

1 - Rear window Removing rear window Installing rear window 2 - Gasket For rear window wiper 3 - Sealing lip (component part of pre-coating) 4 - PUR adhesive sealant Cross section of bead: Width 7 mm; Height 11 mm (including pre-coating, residual material on window glass and window flange) Curing time Page 64-38 Page 64-19 Page 64-23

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5 - Trim 6 - Heated rear window contact 7 - Dimension a 4.5 mm (0.18 in.)

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Undamaged rear window, removing (Golf)

- Remove rear lid trim.

Repair Manual, Body Interior, Repair Group 70 - Disconnect wiring connections for heated rear window and press contact tabs onto window. - Remove rear window wiper motor.

Repair Manual, Electrical Equipment, Repair Group 92 - Remove center mounted brake light.

Repair Manual, Electrical Equipment, Repair Group 94 - Loosen sealing lip from window flange with plastic wedge and spray in cleaning solution D 009 401 04 (as a substitute for lubricant).

- With help of handle -1- guide trimming needle -2- under sealing lip -3- and puncture adhesive bead (use on lower edge of rear window). Note: The trimming needle must be guided as close as possible to the window. - Unscrew handle and pass cutting thread through eye of needle.

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- Pull cutting thread toward interior (use pliers and gloves). - Guide cutting thread in between sealing lip and window flange with help of tube -1(cutting wire may also be used if thread breaks). If gap is too small guide cutting thread on outside and push under lip with a plastic wedge.

- Place cutting thread around rear window as shown. Note: Press in cutting thread deep enough to avoid damaging the sealing lip and/or spacing lip. - Pull end of thread in toward interior and secure to pulling handle VAG 1351/1 to counter-hold.

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- Cover inside of window flange -1- with textile reinforced adhesive tape (only when using cutting wire). - Secure inner end of thread on winding device. - Place winding device VAG 1654 in "Position I". - Move winding device according to position required and cut window free. Note: Press cutting thread against window glass with plastic wedge during cutting process, in order to have clearance at window flange.

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Broken rear window, removing (Golf)

Warning! Always wear protective goggles and leather gloves. - Cover areas of body and interior to protect against damage from glass splinters. - Remove pieces of glass up to adhesive sealing material. - Disconnect wiring connectors for heated rear window and antenna. - Cover flange -2- all around with textile reinforced adhesive tape. - Cut through adhesive sealing material (with remainders of glass) in window opening with electric cutter and blade VAG 1561/10 (with stop roller).

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Rear window, installing (Golf)

Preparing old undamaged window for glazing Page 64-31 . Preparing new window for glazing 32 . Preparing body flange for glazing 35 . Installation instructions Page 64Page 64-

Page 64-36 .

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Rear window, assembly overview (Jetta)

1 - Rear window Removing rear window Installing rear window Page 64-26 Page 64-30

2 - Dimension a = 3 mm (0.19 in.) 3 - Sealing lip (component part of pre-coating) 4 - PUR adhesive sealant Cross section of bead: Width = 7 mm (0.28 in.); Height = 11 mm (0.43 in.) (including pre-coating, residual material on glass and window flange Curing time Page 64-38

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5 - Dimension b = 6.5 mm (0.255 in.) Check gap measurement with gauge 3371 6 - Window adjuster Part No. 443 845 631 A 7 - Dimension c = 3 mm (0.19 in.)

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Undamaged rear window, installing (Jetta)

- Disconnect wiring connections for heated rear window and press contact tabs onto window. - Remove hatshelf.

Repair Manual, Body Interior, Repair Group 70 - Remove upper C-pillar trim.

Repair Manual, Body Interior, Repair Group 70 - Loosen sealing lip from window flange with plastic wedge and spray in cleaning solution D 009 401 04 (as a substitute for lubricant).

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- Place cutting thread with help of small tube into window flange Note: Place cutting thread in deep enough so that damage to lip or spacer rib is avoided. - Pull cuttting thread with awl (from VAG 1474A) through adhesive seal material into vehicle interior.

- Pull outer thread inward and hold rigid with pull handle VAG 1351/1. - Fasten thread end (inner) to winding device. - Positon winding device. - Slide protective film -1- (VAG 1474/14) between rear window glass and headliner.

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- Position winding device as necessary to cut window free. Note: Press cutting thread against window glass with plastic wedge during cutting process, in order to have clearance at window flange.

Instead of winding device shown above (VAG 1654), tool VAG 1654A can also be used. The suction can be removed from the tool and the roller can be guided tighter on the glass flange.

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Broken rear window, removing (Jetta)

Warning! Always wear protective goggles and leather gloves. - Cover areas of body and interior to protect against damage from glass splinters. - Remove pieces of glass up to adhesive sealing material. - Disconnect wiring connectors for heated rear window and antenna. - Cover flange -2- all around with textile reinforced adhesive tape. - Cut through adhesive sealing material (with remainders of glass) in window opening with electric cutter and blade VAG 1561/10 (with stop roller).

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Rear window, installing (Jetta)

Preparing old undamaged window for glazing Page 64-31 . Preparing new window for glazing 32 . Preparing body flange for glazing 35 . Installation instructions Curing time Page 64Page 64-

Page 64-36 .

Page 64-38

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Preparing removed undamaged window for installation

Note: When re-using an undamaged window, cut back residual adhesive sealing compound to 1 - 2 mm just before re-bonding. Do not damage primer and ceramic coating during this procedure. Residual material serves as adhesion base for newly applied adhesive sealing compound. WARNING! Do not prime the adhesive surface and do not treat with a cleaning solution. Keep the adhesive surface free of dirt and grease. Exception: If bonding is not performed immediately after cutting back, the remaining residual material must be activated with activator AMV 181 800 02.

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Preparing new window for glazing

New windows are supplied pre-coated with PUR. The pre-coating consists of items 1, 2 and 3: 1 - Sealing lip 2 - Spacing lip 3 - Area for application of adhesive bead 4 - Window glass Side window Note: Changes to the side window pre-coating material require that the pre-coating be treated as follows: - Soak a cloth with silicone remover, Part No. LSE 020 100 A3-. - Clean area for adhesive bead -3- thoroughly using soaked cloth twice. - Coat window with activator AMV 181 800 02 after a flash-off period of at least 5 minutes, as with previous pre-coated windows.

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Side window gaps A gap of 5 - 6 mm (0.20 - 0.24 in.) between top edge of window and window flange on side panel must be adhered to when installing a side window. Note: The distance is required to install the mountings for the roof load system.. The rest of the adhesive sequence remains unchanged.

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All other windows - Rub down pre-coating with a dry cloth which is not fluffy. WARNING! Do not prime precoating and do not treat with cleaning agent. - Apply a thin coat of activator AMV 181 800 02 only onto pre-coating -2- of window using applicator -1-, Part No. D 009 500 25 (felt ball with wire handle). - Allow activator to air dry for at least 10 minutes. Note: Activator must not have contact with paint, otherwise the paint finish will be damaged. Activator must not come into contact with the window heater bus bar.

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Preparing body flange for glass installation

- Cut back remaining material on window flange with scraping blade VAG 1561/8, but do not remove completely. Note: Remaining material is required as a base for better adhesion of the new coat of adhesive sealing material to be applied. Keep dirt and grease off of adhesive surfaces. WARNING! Activator must not have contact with paint, otherwise the paint finish will be damaged. Exception: If the bonding is not carried out immediately after cutting back the remaining material, it must then be activated. If the window flange has been repaired or partially replaced, after painting the area concerned must be cleaned and primed again.

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Installation instructions
Note: The 1K window adhesive DH 009 100 must be heated in a cartridge heater such as VAG 1939 or equivalent, for 20 minutes. - Apply adhesive material (continuous bead) to pre-coating -1- with applicator at right angle to window. WARNING! Window must be installed within 10 minutes, otherwise the adhesive properties of the sealant will be impaired. - Install glass in window opening using two double suction cups (VAG 1344), center and press in onto spacing lip. Note: Windshield gap/shut line Page 64-4 .

Secure windshield during curing time with windshield/window adjusters (Part No. 443 845 631 A). Replace stickers (e.g. for airbag). - Place mirror -1- in position, turned 60 to 90 until locking spring clicks into place. from mounted position, and rotate (arrow)

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Insert seal for rear window wiper motor drive shaft into rear window. Jetta models: Check the gap dimension between the rear lid and rear glass with gauge 3371. Rear window gaps/shut lines Page 64-17 .

The activator must not come into contact with the window heater bus bar. Secure rear window glass in position with adhesive tape during the curing process. Jetta models: Position rear glass during curing time with adjuster, Part No. 443 845 631 A. If the adhesive bead has been applied too thick and the adhesive expands onto the area of the window heating, then the excess adhesive must be removed.

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Curing time
Curing time is the amount of time from the bonding of the window to putting the vehicle into use. During the curing time the vehicle must stand on a level surface at room temperature >15 C (59 F). Window Windshield Side window Rear window WARNING! The vehicle is only safe to use after the curing time is completed. Window adhesive D 004 300 05 D 004 300 05 D 004 300 05 Curing time 4 hours 1 hour 1 hour

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Touching up paint damage

Paint composition is to be restored and corrosion protection measures performed according to specification. The following repair method is suitable for paint finish damaged in a zone which is not visible: Paint over twice (wet-on-wet) with glass/paint primer D 009 200 02. Air drying time = approx. 10 minutes.

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Cleaning off surplus adhesive sealing material

It is recommended to use adhesive remover D 002 000 10 as a cleaning solution. Application of this product requires conformance with safety precautions. WARNING! Glass which has just been installed should not be pressed outward while cleaning from inside the vehicle. - Clean painted surface roughly with a dry cloth. Remove remaining adhesive with adhesive remover D 002 000. 10. Cleaning plastic trim Allow adhesive sealing material to cure (approx. one hour) and then peel off.