Assembly Unit
Assembly Unit
Special tools, testers and auxiliary items required
• Window removing kit (V.A.G 1755)
• Cutting tools for glass (V.A.G 1351)
Removing
- Glass Panel, Removing
- Remove the windshield.
- Remove headliner..
- Tape off the surrounding components to protect the paint from being damaged.
- Stick the needle - 1 - with the handle, from the window opening-set (V.A.G 1755) , under the frame - 2 - through the adhesive bead.
- Remove the handle and thread the cord (357 853 999 A) through the needle.
- Using the pliers, pull the needle - 1 - along with the cord - 2 - through the adhesive bead.
- Tighten the cord at both ends each with a handle from the window opening-set (V.A.G 1755).
A second technician is required for detaching the adhesive bead.
- One person pulls out and the other pulls inward.
- Start at the front right corner - 1 - and cut the adhesive bead all around - 2 - to the center in the front area.
• Plastic centering pins are located in the rear corners. These can be cut by careful "sawing".
• 2 adhesive beads are located on the front roof crossmember and require greater force.
- If the adhesive bead is cut through all the way up to the center on the front crossmember, then the cord is relocated one time.
- Start from the front right - 1 - again. And cut through the adhesive bead on the front crossmember for this side - 3 -.
Installation
Special tools, testers and auxiliary items required
• Double cartridge gun (VAS 5237)
• Cartridge gun (V.A.G 1628)
• Cartridge heater (V.A.G 1939)
Materials
• For the part numbers for the different materials, refer to the => Parts Catalog.
• Follow the manufacturer instructions supplied with the package.
* 1) Follow the manufacturer instructions supplied in the packaging.
* 2) Note the minimum curing time. Refer to => [ Minimum Curing Time ] Spoiler.
* 3) The cartridge gun (V.A.G 1628) must be used with this material.
* 4) Warm with the heater cartridge (V.A.G 1939) according to manufacturer instructions.
* 5) The double cartridge gun (VAS 5237) must be used with this material.
* 6) For the part numbers of the different materials, refer to the => Parts Catalog.
Preparing Body Flange for Adhesion
- Cut back remaining material on the body flange using U-shape scraper (V.A.G 1561/3) , do not remove all residue under any circumstance.
• The remaining material serves as a base for the new adhesive sealant being applied. Keep the adhesive surfaces free of dirt and grease.
Exception: If the bonding is going to be performed longer than one day after cutting back the adhesive bead, then then remaining material must be activated with the activator (D 181 801 A1).
Apply the activator evenly and in one wiping motion using the applicator (D 009 500 25).
Do not let the activator come in contact with the paint because this will damage the paint.
Drying time is approximately 10 minutes
• If the window flange is being repair or partially replaced, the corresponding area must be clean and primed again before painting.
Installing
- Apply the adhesive sealing material all around the circumference at a right angle to the frame.
The frame must be installed within 10 minutes or the adhesive will not bond well.
Do not apply the adhesive bead too thickly and do not press the frame too firmly onto the body flange.
• Place the frame in the opening, center it, and press it onto the spacer.
Minimum Curing Time
There are special requirements for replacing the bonded sunroof frame. This includes, for example, a newly bonded sunroof frame is safe for vehicle operation also in case of an accident after a specified minimum curing time.
The minimum curing time for 2K window adhesive is 2 hours for the frame.
Curing time means the time from when the sunroof frame is bonded to when the vehicle is put back into use. During this time, the vehicle must stand on an even surface at room temperature (at least 15 °C).
The vehicle is operationally ready only after the minimum curing time has elapsed.
• Cut back the remaining adhesive sealant to 1...2 mm shortly before re-adhering, do not damage the primer coating.
• The remaining material serves as a base for the new adhesive sealant being applied.
Do not prime the adhesive surface or use a cleaning solution on it. Keep the adhesive surface free of dirt and grease.
Exception: if adhesion is not performed immediately after the adhesive sealing material is cut, the remaining material must be activated using activator D 181 801 A1.
- Check whether all of the height stops - 3 - are present.
- Apply the adhesive. Dimensions for adhesive bead - 2 -: width 12 mm, height 10 mm.
• To install the assembly frame, the glass panel must first be installed.
- Insert the frame with the glass panel into the opening.
New Frame
- The centering pins - 2 - center the frame in the opening.
- Press in the frame all the way until it stops. Then check the height adjustment to the roof.
Existing Frame
- Since the centering pin is no longer present, align the frame in the roof opening.
- Press in the frame all the way until it stops. Then check the height adjustment to the roof.
Adhesive Sealant, Removing from Window
- Using adhesive remover is recommended. Always follow the safety precautions when using adhesive remover.
When cleaning from vehicle interior out, the sunroof frame that was just installed must not be pressed outward.
- Clean the painted surface with a dry cloth. Clean off any dirt with adhesive remover.
- Clean the plastic trim: let the adhesive sealant harden for approximately 1 hour and then peel it off.