64-1

Windows, removing and installing

Tools and materials, overview

New windows

Supplied pre-coated with PUR adhesive, parts -1-, -2- and -3-

1 - Sealing lip

2 - Spacing lip

3 - Area for application of cement bead

4 - Window glass

Tools

CAUTION!

Part numbers are listed for reference only. Always check with your Parts department for the latest information.

VAG1654 winding device

Cutting thread 357 853 999

Cutting wire 357 845 955 (not shown)

64-2

VAG1561 electric cutter

VAG1561/10 blade with stop roller

For cutting down adhesive material on window glass.

VAG1561/8 scraping blade

For cutting down adhesive material on window flange.

Note:

Handle -1- and trimming needle -2- are commercially available tools.

VAG1755 repair kit

1 - Handle

2 - Trimming needle

3 - Tube (for pulling in cutting thread or cutting wire)

4 - Plastic wedge

64-3

VAG1628 cartridge gun

VAG1344 double suction cup

Cartridge heater VAG1939

64-4

Bonded windows, removing and installing

Tools and materials

Cartridge heater VAG1939

1K- Adhesive........DH 009 100 2), 4)

1K- Adhesive........DH 009 100 03 2), 4), 5)

2K- Adhesive........D 004 300 05 2), 3)

Activator........AMV 181 800 02 1)

Glass primer/paint primer......D 009 200 02 1)

Cleaning solution........D 009 401 04 1)

Primer-applicator........D 009 500 25 1)

Adhesive remover........D 002 000 10 1)

1) Materials are stored in the box D 004 700.

2) Note curing time page 64-21 .

3) Only use for windshield and side glass.

4) Heat according to manufactures specifications with cartridge heater VAG1939.

5) Small cartridge 110 ml (for sealing or if the 300 ml cartridge is insufficient).

CAUTION!

Part numbers are listed for reference only. Always check with your Parts department for the latest information.

64-5

Bonded windshield, assembly overview

1 - Windshield

Removing page 64-6

Installing page 64-8

2 - Ceramic layer

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 window glass and flange)

5 - Molded headliner

6 - Rear-view mirror mounting plate

PUR adhesive

7 - Eccentric

To adjust window gap at top

8 - Window gap

Gap a- = 4 mm (0.157 in.)

64-6

Bonded windshield, removing

WARNING!

Always wear protective goggles and leather gloves when removing and installing windshield.

- Unclip roof molding strips in A-pillar area.

- Remove front wiper arms (M8 hex nuts).

Tightening torque: 20 Nm (15 ft lb)

- Loosen screws -1- several turns (relieving tension from clip) and remove with clip.

- Remove seal -3- and remove plenum cover -4-.

- Turn eccentric counterclockwise set back from glass.

- Twist to remove inside rear-view mirror from adhesive plate.

- Remove sun visors (this provides clearance between window flange and molded headlining).

- Remove trim from A-pillars page 70-23 .

- Loosen sealing lip from window flange and spray in cleaning solution D 009 401 04 (as substitute for lubricant).

- Place cutting thread in window flange with help of tube (from VAG1755) (cutting wire may also be used).

64-7

- Pull cutting thread through adhesive sealing material into inside of vehicle with broach (from VAG1474). Cutting thread is double up to windshield wiper shaft

- Secure outer end of thread to windshield wiper shaft.

- Secure inner end of thread to winding device.

- Attach VAG1654 winding device in position -I-.

- Move winding device to position -II-, position -III- and so on as necessary, and cut out windshield glass.

- Press cutting thread against window glass using plastic wedge during cutting process, in order to have access at window flange and instrument panel.

64-8

Bonded windshield, installing

Preparing old window for re-installation page 64-17

Preparing new window for installation page 64-18

Preparing body flange for window installation page 64-19

Installation instructions page 64-20

Curing time page 64-21

64-9

Bonded rear window, assembly overview

1 - Rear window

Removing (window unbroken) page 64-10

Removing and installing (window broken) page 64-12

2 - Ceramic layer

3 - Sealing lip (component part of pre-coating)

4 - PUR adhesive sealant

Cross section of bead

Width = 7 mm (0.28 in.)

Height = 12 mm (0.47 in.) (including pre-coating, residual material on window glass and flange)

64-10

Bonded rear window unbroken, removing

WARNING!

Always wear protective goggles and leather gloves when removing and installing windshield.

- Remove rear wiper arm (M8 hexagon nut).

Tightening torque: 15 Nm (11 ft lb)

- With plastic wedge loosen sealing lip from window flange all around, and spray in cleaning solution D 009 401 04 (as substitute for lubricant).

Note:

The trimming needle must be guided as close to the window as possible (do not damage heater element).

- With help of handle -1-, guide trimming needle -2- under sealing lip and puncture through adhesive bead (use side areas).

- Remove handle and pass cutting thread through eye of needle.

- Pull cutting thread towards inside (use pliers and gloves).

- Guide cutting thread between sealing lip and window flange with help of tube -3- (cutting wire may also be used).

- If gap is too small, guide cutting thread on outside and push under lip with a plastic wedge.

64-11

Note:

Press in cutting thread deep enough in order to avoid damaging the sealing lip and/or spacing lip.

- Place cutting thread around rear window as shown.

- Secure outer end of thread to window wiper shaft, or pull end of thread toward inside and counterhold with VAG1351/1 pulling handle.

- Disconnect electrical connectors for heated rear window and press connecting terminals onto window

- Cover inside of window flange -3- with fabric-reinforced adhesive tape.

- Secure inner end of thread on winding device.

- Attach VAG1654 winding device in position -I-.

- Move winding device to position -II-, position -III- and so on as necessary and cut out window glass.

- Press cutting thread against window glass using plastic wedge during cutting process, in order to have clearance at window flange.

64-12

Bonded rear window broken, removing and installing

WARNING!

Always wear protective goggles and leather gloves.

Installing

Preparing used window for re-installation page 64-17

Preparing new window for installation page 64-18

Preparing body flange for window installation page 64-19

Installation instructions page 64-20

Curing time Page 64-21

- Protect body and interior against damage from glass splinters.

- Remove as many pieces of glass as possible, up to adhesive sealing material.

- Disconnect electrical connectors for heated rear window.

- Cover flange -2- with fabric-reinforced adhesive tape.

- Cut through adhesive sealing material (with remaining pieces of glass) in window opening with electric cutter and VAG1661/10 blade (with stop roller).

64-13

Bonded side window, assembly overview

1 - Side window

Removing (window unbroken) page 64-14

Removing (window broken) page 64-12

Installing page 64-16

2 - Ceramic layer

3 - Sealing lip (component part of pre-coating)

4 - PUR adhesive sealant

Cross section of bead

Width = 7 mm (0.28 in.)

Height = 12 mm (0.47 in.) (including pre-coating, residual material on window glass and flange)

5 - Retaining clips

64-14

Bonded side window, removing

WARNING!

Always wear protective goggles and leather gloves.

Removing unbroken window

- Remove side trim page 70-34 .

- Remove side support for luggage compartment cover page 70-36 .

- Loosen C-pillar trim page 70-28 .

- 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 substitute for lubricant).

- With help of handle -1-, guide trimming needle -2- under sealing lip and puncture through adhesive bead.

Note:

The trimming needle must be guided as close as possible to the window.

64-15

- Remove handle and pass cutting thread through eye of needle.

- Pull cutting thread toward inside (use pliers and gloves).

- Guide cutting thread between lip and window flange with help from tube -1-.

If cutting thread should break, 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 on door latch striker pin (apply layer of fabric-reinforced adhesive tape along thread path to protect finish).

- Secure inner end of thread on VAG1654 winding device and cut out window by moving winding device as necessary.

- Press cutting thread against window glass with plastic wedge during cutting process, in order to have access at window flange.

64-16

Removing broken window

Refer to the procedure for removing a broken rear window page 64-12

Installing

Preparing old window for re-installation page 64-17

Preparing new window for installation page 64-18

Preparing body flange for window installation page 64-19

Installing instructions pages 64-20

Curing time page 64-21

64-17

Window (used), preparing for installation

Note:

When installing an undamaged window, cut back the remaining adhesive sealing material -1- to thickness of 1 to 2 mm (0.04 - 0.08 in.) using an electric cutter and VAG1561/10 blade with stop roller. Do not damage the pre-coating or the sealing lip with spacing lip -2-.

CAUTION!

Note:

If the window is not installed (bonded) immediately after cutting back the old

- Do not damage spacing lip -1- or ceramic layer -2-.

Do not prime adhesive surface, do not activate and do not treat with cleaning agent.

Keep adhesive surface clean and free of grease.

adhesive material, it must be activated before installation page 64-18 .

64-18

Window (new), preparing for installation

New windows are supplied pre-coated with PUR adhesive, parts -1-, -2- and -3-.

CAUTION!

1 - Sealing lip

2 - Spacing lip

3 - Area for application of adhesive bead

4 - Window glass

- Rub down pre-coating using dry cloth that is not fluffy.

DO NOT prime pre-coating and do not treat with cleaning agent.

Keep adhesive surface clean and free of grease.

CAUTION!

Activator must NOT have contact with paint, otherwise the paint finish will be damaged.

- Apply thin coat of activator AMV 181 800 01 only on window pre-coating -2- using applicator -1- (D 009 500 25 felt ball with wire).

- Allow activator to air dry for at least 10 minutes.

64-19

Window flange (body), preparing for window installation

Notes:

CAUTION!

- Cut back remaining material on window flange using VAG1561/8 scraping blade, but do not remove it completely.

The 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 adhesive surfaces.

If the window is not installed (bonded) immediately after cutting back the old adhesive material, it must be activated before installation.

If the window flange has been repaired or partially replaced, the affected area must be cleaned and primed again after painting.

Do not prime the adhesive surface, do not activate and do not treat with a cleaning solution.

Keep the adhesive surface free of dirt and grease.

Activator must NOT have contact with paint, otherwise the paint finish will be damaged.

64-20

Window installation instructions

Note:

The 1K window adhesive DH 009 100 must be heated in VAG1939 cartridge heater for 20 minutes.

CAUTION!

CAUTION!

If the adhesive bead has been applied too thick and the adhesive expands onto the area of the window heater, then the excess adhesive must be removed page 64-29 .

- Apply adhesive material to pre-coating -1- all around at right angle to window.

The glass panes must be installed within 10 minutes of the adhesion application or the adhesion properties will be affected.

Part numbers are listed for reference only. Always check with your Parts department for the latest information.

- With help of two double suction cups (VAG1344 or equivalent) install glass pane, center it in window opening, and press in onto spacing lip.

- Hold window glass in position with adhesive tape during curing process.

64-21

Curing time

Curing time: From the installation of the glass until the vehicle is ready for operation.

During curing time the vehicle must be parked on a level surface at room temperature, above 15 C (59 F).

Note:

The specified curing time is based on the use of adhesives and sealants specified by Volkswagen

Window Vehicle Adhesive Curing time

Windshield without airbag

DH 009 100 / 03

4 hours

with airbag

DH 009 100 / 03

16 hours

without airbag

D 004 300 05

1 hour

with airbag

D 004 300 05

4 hours

Side DH 009 4 hours

window 100 / 03

D 004 300 05

Rear window

DH 009 100 / 03

4 hours

WARNING!

Vehicle is only safe to drive after curing time is completed.

64-22

CAUTION!

ALWAYS follow the manufacturer's instructions for the adhesive/sealing material being used to install window glass.

Part numbers are listed for reference only. Always check with your Parts department for the latest information.

64-23

Door window regulator, removing and installing

Door window, removing page 57-10

- Remove cable clip (arrow).

- Loosen hex-head screws -1- and -2-.

- Lift window regulator slightly so that hex-head screws -1- can be pulled through installation openings.

- Pull window regulator out downward through installation opening.

- Install in reverse order of removal.

Tightening torque (screws -2-): 10 Nm (7 ft lb)