Rear Window
Rear Window
Special tools, testers and auxiliary items required
• Suction lifter (V.A.G 1344)
• Awl (V.A.G 1474/2) from the removal kit for flush bonded windows (V.A.G 1474B)
• Electric cutter (V.A.G 1561A)
• Angled blade (V.A.G 1561/10)
• Spooling tool (V.A.G 1654A)
• Cartridge heater (V.A.G 1939 A)
Special tools, testers and auxiliary items required
• Double cartridge gun (VAS 5237)
• Protective eyewear
• Leather gloves
Removing
Proceed as follows:
- Remove the bottom center trim => [ Lower Center Trim ] .
- Remove the right engine compartment trim => [ Left and Right Engine Compartment Trim ] Left and Right Engine Compartment Trim.
- Disconnect and free up the electrical connectors - 1 - and - 2 -.
- Disconnect and free up the wiring harness to the engine compartment lid antennas.
- Remove the right vent grille => [ Vent Grille ] .
• If the rear window will be installed again, secure the wiring harness to the side window with adhesive tape on the rear window to protect it from damage - arrows -.
CAUTION!
Risk of injury!
• Wear protective eyewear.
• Wear leather gloves.
Undamaged rear window, removing
- Pierce the awl (V.A.G 1474/2) through the window adhesive bead from the inside to the outside.
- Thread the cutting cord - 1 - into the awl (V.A.G 1474/2) and pull it in.
- Route the cutting cord - arrow - all the way around under the edge of the rear window.
- Loop the end of the cutting cord - 1 - through the bracket and secure it on the gas-filled strut ball stud - arrow -.
- Secure the end of the cutting cord in the reel device (V.A.G 1654A).
- Free up the right side of the rear window.
• Make sure the cutting cord does not damage the rear window defroster electrical connectors.
- Position the reel device (V.A.G 1654A) as shown in the illustration.
- Free up the bottom edge of the rear window.
- Position the reel device (V.A.G 1654A) as shown in the illustration.
- Free up the left side of the rear window.
• Make sure the cutting cord does not damage the rear window defroster electrical connectors.
- Position the reel device (V.A.G 1654A) as shown in the illustration.
- Free up the upper side of the rear window.
- Position the reel device (V.A.G 1654A) as shown in the illustration and free the rear window up completely.
- Remove the rear window from the window opening using the suction lifter (V.A.G 1344).
Damaged rear window, removing
- Protect the body and engine compartment from glass splinters.
- Remove glass pieces from adhesive material.
- Bond flange all around with fabric reinforced adhesive tape.
- Cut through the adhesive sealing material (with the remainder of the glass) in the window opening using the electric cutter (V.A.G 1561A) and angled blade (V.A.G 1561/10) (with stopper roller).
Preparations for installing rear window
- When reusing an undamaged rear 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.
New rear window
- Clean the window all around in the adhesive area using cleaning solution (D 009 401 04).
- Apply glass and paint primer (D 009 200 02) all around in the adhesive area.
• Drying time approximately 10 minutes.
CAUTION!
Ceramic application on window is not primer! It must be primed before the application of adhesive sealing material!
- Install the spacer buffer - arrows - according to the markings on the rear window.
- Bond the adhesive stop profiles - 1 - and - 2 - parallel near the rear window defroster distributing wire.
Window flange
- If the window flange was damaged, recreate the paint structure => Vehicle Paint and apply corrosion protection if necessary => Surface Technology/Chemical Materials.
- First clean the repaired area with cleaning solution (D 009 401 04) and then apply glass and paint primer (D 009 200 02).
Applying primer
- Apply primer - 2 - along circumference evenly and in one motion using an applicator - 1 -.
- Begin applying with saturated felt.
• Primer width dimension: Dimension - a - is approximately 20 mm.
• Primer location: centered to the adhesive bead.
• Drying time approximately 10 minutes.
CAUTION!
Primer conducts electricity and must not touch rear window defroster distributing wire.
Installing
- Install the right vent grille => [ Vent Grille ] .
- Cut the nozzle tip as shown in the illustration.
• Dimension - a - 12 mm
• 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 + 2 mm.
• Dimension - b - =13.5 + 3.0 mm.
• Dimension - c - = varying spacing dimensions to window edge => [ Rear Window Assembly Overview ] Rear Window Assembly Overview.
- Position the entire surface of the nozzle - 2 - on the rear window.
• Application direction - arrow - for adhesive bead - 1 -.
- Apply adhesive sealing material - 1 - all around the rear window as shown in the illustration.
- When using an undamaged removed rear window, apply adhesive to the remaining bead.
CAUTION!
The adhesive sealing material must not come into contact with the rear window defroster distributing wire.
- Note varying spacing dimensions to window edge => [ Rear Window Assembly Overview ] Rear Window Assembly Overview.
- Insert the rear window in the window opening using the suction lifter (V.A.G 1344).
CAUTION!
• Install the rear window within 15 minutes or the adhesive bonding ability will be reduced.
• If the adhesive sealing material leaks out at the lower edge when inserting the rear window, remove it immediately.
- Center the sides of the rear window between the vent grilles; installation dimensions => [ Rear Window Assembly Overview ] Rear Window Assembly Overview.
- Observe minimum curing time => [ Minimum curing times ] Flush-Bonded Windows.
- Secure the rear window defroster and antenna wiring harness in the engine compartment lid.
- Install the bottom center trim => [ Lower Center Trim ] .