Back Window Glass: Service and Repair

Rear Window, Avant

Damaged Rear Window



Undamaged Rear Window

Removing

CAUTION!
Always wear protective glasses and leather gloves when removing a window.

- Remove rear lid trim.

- Remove rear window wiper motor.

- Disconnect electrical harness connectors for heated rear window and antennas.

- Pull off side sealing strip at rear window.

- Open rear lid.





- Pierce through adhesive sealing material using a guide needle with handle - 1 - from (V.A.G 1755) window removing kit.

- Remove handle and thread end of cutting cord through eye of the guide needle.

- Pull cutting cord end - A - inward (use pliers and protective gloves) to opposite window side with guide needle from ( V.A.G 1755) window removing kit.





- Using plastic wedge, loose sealing lip from glass flange and spray with D009 401 04 cleaning solution (lubricant replacement).





- Insert cutting cord end - B - around rear window using small tube from (V.A.G 1755) window removing kit.

- Using needle and handle, pull second cutting cord end - B - inward as shown.





• Cutting cord ends - A - and - B - may not be pulled diagonally.

- Thread in cutting cord end - A - into spooling tool (V.A.G 1654) and secure.

- Remove cover - 1 - for rear lid hinge and cable guide - 2 - from rear lid hinge - arrows -.





- Fasten cutting cord end to lid hinge.





- Fasten (V.A.G 1654) spooling tool as shown to rear window.





- When cutting side area, press cutting cord in- direction of arrow -.

- Cut glass free at bottom.

- Move winding device as shown, and continue to cut window free.





- When cutting lower area, press cutting cord in - direction of arrow -.

- Cut glass free at side.

- Move winding device as shown, and continue to cut window free.

- When cutting side area, press cutting cord in - direction of arrow -.





- Cut glass free at top.

- Move winding device as shown, and continue to cut window free.

- When cutting upper area, press cutting cord in - direction of arrow -.





- Cut window away completely and lift out from rear lid.



Damaged

Removing

CAUTION!
Always wear protective glasses and leather gloves when removing a window.

Protect body and interior from glass splinters.

- Remove glass pieces up to adhesive material.

- Disconnect connections for heated rear window and antennas.

- Bond flange all around with fabric reinforced adhesive tape.

- Remove adhesive sealing material (with glass residue) from window opening using electric cutter and knife (V.A.G 1561/10) (with stopper roll).

Preparing for Window Installation

• If windshield flange was damaged during removal, paint structure should be repaired according to specifications in Repair Information, "Vehicle-Paint " and if necessary, corrosion repair measures should be taken according to guidelines in "Surface Technology/Chemical Materials Folder".

For undamaged removed windshield

- When reusing an undamaged window, cut back smoothly residual adhesive sealing material on window and flange using electric cutter (V.A.G 1561A) and scraper (V.A.G 1561/8); 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 window, installing

- Clean windshield in adhering area using D 009 401 04 and prime using D 009 200 02 glass/paint primer.

CAUTION!
•

• For this purpose, apply adhesive stopper profile next to distributing wire on new replacement windows.

Applying primer

- Apply primer - 2 - D 009 200 02 uniformly all around on window, centering by markings, using applicator - 1 -, Part No. D 009 500 25 (felt ball with wire).





- This determines the distance to window edge - dimension b -.

- Primer width - dimension a - is determined by the markings on window.

- Begin application with a fully saturated felt. Air drying time approx. 10 minutes.

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

• Do not touch up primer strip until after primer has thoroughly dried.

Adhesive bead cross section





1 Adhesive bead
2 Primer
3 Washer

• Dimension - a - = 8 ± 2 mm.

• Dimension - b - =13.5 ± 1.5 mm.

• Dimension c is determined by markings on window

Installing

- After preparatory work has been performed, apply the adhesive.

- Position complete surface of nozzle - 2 - onto window.





- - Arrow - indicates direction of application

• Cross-section thickness of adhesive bead - 1 - is determined by dimension of opening in nozzle tip and rate of application.

- Apply adhesive sealing material all around, as shown in illustration.





- Note varying spacing dimensions to window edge.

- Using two double suction cups, install rear window in window opening.

CAUTION!
Window must be installed within 15 minutes, otherwise bonding properties of adhesive will be impaired.

- Align windshield at sides.

- Secure window glass in windshield opening using adhesive tape during curing process.

- Observe curing time.