Windshield, Removing And Installing: Notes

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Remove the windshield wiper arms. Refer to WINDSHIELD .
Remove the left center and right sun visor. Refer to ROOF TRIM PANELS .
Remove the interior rearview mirror. Refer to INTERIOR REARVIEW MIRROR, REMOVING AND INSTALLING .
Remove the left and right upper A-pillar trim panels. Refer to A-PILLAR TRIM PANEL, REMOVING AND INSTALLING .

-- Remove the plenum chamber cover. Refer to PLENUM CHAMBER COVER, REMOVING AND INSTALLING .

-- Remove the seal and the upper retaining strip.

-- Remove the drip rail.

WARNING:

When removing a window, always wear protective eyewear and leather gloves.

-- Unroll with the :VAS6452/1 approximately 6.5 meters of cutting wire (approximately six 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.

Fig 1: Feeding Both Cutting Wire Ends -3- Into Awl -2- & Pull It In

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- 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.

Fig 2: Cutting Windshield Using Wire

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

CAUTION:

The ends of the wire must not be twisted when cutting through the adhesive -arrow-.

-- Mount both reel devices on the inside of the windshield as illustrated.

Fig 3: Mounting Both Reel Devices On Inside Of Windshield

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Insert the ends of the cutting wire -1- into the reel device -2-

Fig 4: Inserting Cutting Wire End Into Reel Device

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Tension the cutting wire and place the protective foil -2- between the instrument panel and the wire

Fig 5: Placing Protective Foil Between Instrument Panel And Wire

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Cut the first section open, while doing this, the wire is guided into the integrated roller -arrow- on the reel device.

Fig 6: Cutting First Section Open

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- 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.

Fig 7: Inserting An Additional Guide Awl -2- Into Adhesive & Secure It To Windshield With Suction Cup

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- If necessary, move the protective film -3- along with the wire and cut the windshield free with the reel device -1-.

-- Move the reel device and the guide awl as illustrated and cut free the section along the >>A-pillar<<.

Fig 8: Moving Reel Device And Guide Awl

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Moved the reel device and guide awl approximately to the center of the windshield.

-- Cut free the windshield up to about the center.

Fig 9: Cutting Free Windshield Up To Center

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Cut free the bottom of the windshield with the second reel device.

Fig 10: Cutting Free Bottom Of Windshield

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Move the reel device upward and insert the guide awl as illustrated.

Fig 11: Moving Reel Device Upward And Insert Guide Awl

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Cut the windshield free moving upward along the >>A-pillar<<.

Fig 12: Cutting Free Windshield Along A-Pillar Upward

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Move the spool over the center of the windshield as well as over the first spool as illustrated and cut free the rest of the windshield along the top.

Fig 13: Moving Spool Over Center Of Windshield As Well As Over First Spool & Cut Free Rest Of Windshield Along Top

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the windshield from the vehicle with the suction cups.

Preparations for Installing the Windshield

-- When reusing the undamaged window, cut the rest of the adhesive material on the window and flange with the :VAG1561A and :VAG1561/8 so it is even, but do not remove it completely.

NOTE:

The remaining material acts as a base for the new adhesive to be applied.

CAUTION:

Keep the adhesive surface free of dirt and grease.
Cut back the adhesive surface shortly before installing.
Do not prime or use a cleaning solution on the adhesive surface.

With New Window

-- Clean all around the window adhesive surface with Cleaning Solution:D 009 401 04 .

-- Apply Glass and Paint Primer:D 009 200 02 as described below.

CAUTION:

Ceramic application on window is not primer! It must be primed before the application of adhesive sealing material!

Applying Primer

Fig 14: Applying Glass/Paint Primer D 009 200 02

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Apply glass-/paint 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.
The glass-/paint primer must be positioned in the center of the adhesive bead.
Curing time 10 minutes

Window Flange

-- If the window glass flange was damaged, the paint must be repaired and corrosion protection must be applied, if necessary.

-- First clean the repaired area with Cleaning Solution:D 009 401 04 and then apply the Glass/Paint Primer:D 009 200 02 .