Side Window
Side Window
Special tools, testers and auxiliary items required
• Pull handle (V.A.G 1351/1) from the cutting tools for glass (V.A.G 1351)
• Electric cutter (V.A.G 1561A)
• Angled blade (V.A.G 1561/10)
• Cartridge gun (V.A.G 1628)
• Cartridge heater (V.A.G 1939 A)
• Pop rivet pliers (VAS 5072)
• Protective eyewear
• Leather gloves
• Drill machine
Removing
Proceed as follows:
CAUTION!
There is a risk of damaging the paint.
• In the window cutting area, protect the paint surfaces on the side panel and roof from damage using adhesive tape.
- Remove the side panel cover: Without fuel filler door => [ Side Panel Cover, without Fuel Filler Door ] ; with fuel filler door => [ Side Panel Cover, with Fuel Filler Door ] .
- Remove the door seal and roof trim molding seal in the side window area => [ Roof Trim Molding ] .
CAUTION!
Risk of injury!
• Wear protective eyewear.
• Wear leather gloves.
- Drill out the upper and lower rivet heads in the B-pillar area on the window and drive out the rivet shafts.
Undamaged side window, removing
- Route the cutting cord around the side window as shown in the illustration.
- Secure each end of the cutting cord in the pull handle (V.A.G 1351/1).
- Pull the cutting cord forward in the - direction of the arrow - with light sawing motions and cut through the adhesive bead on the bottom of the side panel and on the roof frame which also cuts through the securing pins on the side window.
- Remove the side window from the side window opening.
Damaged side window, removing
- Protect body and interior 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 side window
- When reusing an undamaged side window, cut the remaining adhesive sealing material on the side window and flange using a carpet knife so that it is even, but do not remove it 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 side window
- Clean the side 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.
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.
Installing
- 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 => [ Side Window Assembly Overview ] Side Window Assembly Overview.
- Position the entire surface of the nozzle - 2 - on the window.
• Application direction - arrow - for adhesive bead - 1 -.
- Apply adhesive sealing material all around near window molding.
- When using an undamaged removed window, apply adhesive to the remaining bead.
• Use 1K Window Adhesive (DH 009 100 03) (small cartridge), or 2K Window Adhesive Kit (DA 004 600 A2) can also be used if more than one window must be bonded.
CAUTION!
Install the side window within 15 minutes or the adhesive bonding ability will be reduced.
Used side window:
- When using a used side window without securing pins, align the window flush to the roof trim molding seal and the body contour and secure it with adhesive tape while the adhesive cures.
New side window:
- First press the side window onto the C-pillar with the securing pin, then insert it in the window opening and secure it in the B-pillar area with pop rivets.
All:
- Observe minimum curing time => [ Minimum curing times ] Flush-Bonded Windows.
- Press the door seal and roof trim molding seal on in the side window area => [ Roof Trim Molding ] .
- Install the side panel cover: Without fuel filler door => [ Side Panel Cover, without Fuel Filler Door ] ; with fuel filler door => [ Side Panel Cover, with Fuel Filler Door ] .