Volkswagen Golf / Golf Plus. Manual - part 265

 

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Volkswagen Golf / Golf Plus. Manual - part 265

 

 

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1.5.2

Installing plenum chamber cover

WARNING

Striking the plenum chamber cover can cause cracks in the

windscreen.

– Spray windscreen seal -5- with a soapy solution so that ple‐

num chamber cover -1- is easier to press on.

– Place the plenum chamber cover -1- on the windscreen seal

-5- and engage with the windscreen seal -5- starting in the

middle and applying light pressure.

– Install plenum chamber seal -4- and windscreen wiper.

Note

An insert is installed in windscreen seal of new windscreens. Remove this insert before installing plenum

chamber cover.

General body repairs, exterior - Edition 04.2008

1. Flush bonded windows    

181

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1.6

Removing windscreen

– Remove A-pillar trims ⇒  General body repairs, interior; Rep.

Gr.  70 ; Trims, insulation; Pillars and side trims .

– Remove left and right sun visors ⇒  General body repairs, in‐

terior; Rep. Gr.  68 ; Interior equipment; Compartments, covers

and trims .

– Remove interior mirror ⇒  General body repairs, interior; Rep.

Gr.  68 ; Interior equipment; Interior mirror .

– Remove water deflector strips on left and right 

⇒ page 242

– Slide cover -V.A.G 1474/8- between windscreen -1- and dash

panel.

– Thrust awl -V.A.G 1474/2- -2- through adhesive bead.
– Pull cutting cord -3- through adhesive sealing material into in‐

side of vehicle using awl -V.A.G 1474/2- -2-.

– Secure inside end of cutting cord against falling out using pull

handle -V.A.G 1351/1- -3-.

– Loosen sealing lip in upper area of windscreen with a plastic

wedge and spray in cleaning solution D 009 401 04 (as sub‐

stitute for lubricant).

– Place cutting cord -2- using small tube -1- in upper area of

window.

– If gap is too small, guide cutting cord on outside and push un‐

der lip with a plastic wedge.

– Lay cutting cord -2- around window and guide second end of

cord inwards into interior.

• Ensure that cutting cord -2- lies under window in corners.

– Secure other end of cord to reel device -V.A.G 1654 A- .
– Position reel device -V.A.G 1654 A- in “position I”.
– Reposition reel device -V.A.G 1654 A- as necessary and cut

window free.

– Use wedge -V.A.G 1474/5- to press cutting cord against win‐

dow glass while cutting in order to avoid damaging dash panel

and to create clearance at window flange.

1.7

Installing windscreen

Preparing old undamaged window for glazing 

⇒ page 188

Preparing new window for glazing 

⇒ page 188

Preparing body flange for glazing 

⇒ page 190

Installation instructions 

⇒ page 191

General body repairs, exterior - Edition 04.2008

182

     Rep. Gr.64 - Glazing

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Minimum curing period 

⇒ page 191

1.8

Assembly overview - rear window

1 - Rear window

❑ Removing 

⇒ page 183

❑ Installing 

⇒ page 185

2 - Seal

❑ For rear window wiper

3 - Rear lid
4 - PUR adhesive sealant

❑ Cross section of bead:

width = 6.5 mm, height =

10 mm (including resid‐

ual material on window

glass and window

flange)

❑ Minimum curing period

⇒ page 191

5 - Trim

❑ Remove trim ⇒  General

body repairs, interior;

Rep. Gr.  70 ; Trim, in‐

sulation; Rear lid trim/in‐

sulation

6 - Window aerial contact

❑ Right and left

1.9

Removing undamaged rear window

– Remove rear lid trim ⇒  General body repairs, interior; Rep.

Gr.  70 ; Trims, insulation; Luggage/load compartment trims .

– Remove rear window wiper motor ⇒  Electrical system; Rep.

Gr.  92 ; Repairing rear window wipe and wash system .

General body repairs, exterior - Edition 04.2008

1. Flush bonded windows    

183

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– Pull off connections -1- on left and right for heated rear window

and window aerial.

– Thrust awl -V.A.G 1474/2- -1- through adhesive bead.
– Pull cutting cord -2- through adhesive sealing material to in‐

side using awl -V.A.G 1474/2- -1-.

– Secure end of cutting cord -3- against falling out using pull

handle -1-.

– Lay cutting cord -3- around window and guide second end of

cord inwards into interior.

– Secure end of cord to reel device -V.A.G 1654- -2-.
– Position reel device -V.A.G 1654- -2- in “position I”.
– Reposition reel device -V.A.G 1654- -2- as necessary and cut

window free.

– Use wedge -V.A.G 1474/5- to press cutting cord -3- against

window glass while cutting in order to have clearance at win‐

dow flange.

1.10

Removing broken rear window

– Protect body and interior against damage from glass splinters.
– Remove pieces of glass up to adhesive sealing material.
– Pull off connectors for rear window heating and aerial.

General body repairs, exterior - Edition 04.2008

184

     Rep. Gr.64 - Glazing

 

 

 

 

 

 

 

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