Rear Window
Rear Window
Undamaged Rear Window, Removing
- Remove the rear lid trim.
- Disconnect rear window defroster and window antenna connectors and secure to center of window with adhesive tape.
When removing a window, always wear protective eyewear and leather gloves.
- From the wire spool (VAS 6452/1) , pull out approximately 6.5 meter of cutting wire (about 6 turns) and cut it.
- Cover the awl outlet under the body flange with tape - 1 - to prevent damaging it.
- 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.
- Route cutting wire around rear window under the glass as shown in the illustration.
The ends of the wire must not be twisted when cutting through the adhesive - arrow -.
- Mount both spools on the inside of the windshield as illustrated.
- Insert the ends of the cutting wire- 1 - into the spool - 2 -
- Tension the cutting wire using the spool - 1 - and insert the plastic film - 2 - taken from the cutting tool kit (VAS 6452) to protect the wire and the rear shelf.
- Cut free the windshield along the D-pillar downward.
- Move the reel device as illustrated.
- The wire is guided into the integrated roller - arrow - on the spool.
- Cut the window free on the left lower corner.
- Move the reel device as illustrated.
- Insert an additional guide awl 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.
- Cut the window free on the lower edge of the glass to the right.
- Move the spool and the guide awl as illustrated and cut free the section along the D-pillar.
- Move the reel device as illustrated.
- Cut the window free on the right lower corner.
- Move the reel device as illustrated and install the guide awl.
- Cut top of window free.
- Move the reel device as illustrated.
- Cut the window free on the right upper corner.
- Mount the guide awl as illustrated and the window free on the D-pillar upward.
- Move the window glass over to the left corner of the window and cut the window free.
- Move the left reel device to approximately the center of the window as illustrated and mount the guide awl.
- Cut the window free along the top to approximately the center of the window.
- Move the right on the right side reel device over the left one as illustrated and cut free the window completely.
- Lift the window out of the rear lid using the suction cups.
Damaged Rear Window, Removing
When removing a window, always wear protective eyewear and leather gloves.
- Protect body and interior from glass splinters.
- Remove glass pieces from adhesive material.
- Disconnect rear window defroster and window antenna connectors.
- Bond flange all around with fabric reinforced adhesive tape.
- Remove adhesive material (with glass residue) from window opening using electric cutter (V.A.G 1561A) and knife (V.A.G 1561/10) (with stopper roll).
Preparations for the installing the rear window
• If an undamaged window is going to be used again, first remove any remaining adhesive on the glass just before installing it and cut the flange using window cutter (V.A.G 1561 A) and scraping knife (25 mm) (V.A.G 1561/8) so that it even, but do not remove completely.
• Residual material acts as a base for the new adhesive sealing material.
• 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.
With new window:
- Clean the window all around in adhesive area using cleaning solution (D 009 401 04).
• The ceramic application on the the window is not a primer.
• It must be primed before the application of adhesive sealing material!
- Apply the glass/paint primer (D 009 200 02) as described.
Applying primer:
- Apply the glass/paint primer - 3 - evenly with one stroke using the applicator - 2 - over the adhesion area on the window - 4 -.
- Beginning applying with saturated felt.
• Curing time 10 minutes
Glass/paint primer conducts electricity and must not touch rear window defroster distributing wire.
Window flange:
- If the windshield flange was damaged, then it must be repainted and if necessary, corrosion protected.
- Clean the repaired area with cleaning solution (D 009 401 04) and then apply glass/paint primer (D 009 200 02).
Installing
• 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. Glass/paint primer
3. Window
• Dimension - A - = 8 mm +/- 2 mm
• Dimension - b - = 12 mm 2 mm
• Dimension - c - = note varying spacing dimensions to window edge. Refer to => [ Rear Lid Window Assembly Overview ] Rear Lid Window Assembly Overview.
- Position the entire nozzle surface - 2 - on the window.
• Application direction - arrow - for adhesive bead - 1 -.
- Apply adhesive sealing material all around.
- With an undamaged removed window, apply adhesive to remaining bead.
- Insert the rear window into window cut-out using suction cups.
The window must be installed within 15 minutes or the adhesive sealing material will not adhere properly.
- Center window along sides.
- Observe minimum curing time. Refer to => [ Minimum Curing Time ] Flush-Bonded Windows.