Volkswagen Golf Variant / Jetta. Manual - part 69

 

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Volkswagen Golf Variant / Jetta. Manual - part 69

 

 

– Secure one end of cord -2- to pull handle -V.A.G 1351/1- -2-

to counterhold.

– Pull other end of cord into vehicle interior.
– Secure other end of cord to reel device -V.A.G 1654 A- -1-.
– Reposition reel device -V.A.G 1654 A- -1- as necessary and

cut window free.

– Use plastic wedge to press cutting cord against window glass

while cutting in order to have clearance at window flange.

– Instead of reel device -V.A.G 1654- , reel device -V.A.G 1654

A- can be used.

– One suction cup can be removed from the reel device -V.A.G

1654- as shown in figure. This ensures that the reel device -

V.A.G 1654 A- roller can be guided closer to the window

flange.

1.13

Removing broken side window (Variant)

Removing a broken side window is performed in the same man‐

ner as removing a broken rear window 

⇒ page 270

 .

1.14

Installing side window (Variant)

Preparing old undamaged window for glazing 

⇒ page 274

Preparing new window for glazing 

⇒ page 274

Preparing body flange for glazing 

⇒ page 275

Installation instructions 

⇒ page 276

Minimum curing period 

⇒ page 276

1. Flush bonded windows    

273

 

glazing

Note

If installing an undamaged window, cut back residual adhesive

seal to 1...2 mm, being careful not to damage primer and ce‐

ramic coating.

Remaining material serves as adhesion base for newly ap‐

plied adhesive sealing compound.

Caution

Do not prime bonding surface and do not treat with a cleaning

solution. Keep bonding surface free of dirt and grease.

Exception: If bonding is not performed immediately after cutting

back, the remaining residual material must be activated with ac‐

tivator -D 181 801 A1- .

1.16

Preparing new window for glazing

Only the applied ceramic layer and injection moulded sealing lip

with spacer rib are found on all new windows.
Exception: rear window does not have a sealing lip or spacing lip.
1 - Sealing lip
2 - Spacing lip
3 - Window

Note

The area on which the adhesive bead is applied is not precoated

or primed.

– Clean a 20 mm wide strip all around edge of window using

cleaning solution -D 009 401 04- .

– Then rub edge of window dry using a lint free cloth.

WARNING

Ceramic coating on window is not primer! It must be primed

before  application  of  adhesive  sealing  compound!  Use  only

primer -D 009 200 02- !

274

 

Ensure that glass adhesive is applied to primed area at a distance

of approx. 2 mm from sealing lip -2-.
Drying time approx. 10 minutes

1.17

Touching up paint damage

If paintwork is damaged, paint structure must be restored accord‐

ing to specifications in “Paint” workshop manual.

1.18

Preparing body flange for glazing

– Cut back remaining material on body flange with electric cutter

-V.A.G 1561 A- and scraping blade -V.A.G 1561/8- , but do not

remove completely.

Note

Remaining material serves as adhesion base for newly applied

adhesive sealing compound. Keep bonding surfaces free of dirt

and grease.

Exception: If bonding is not performed immediately after cutting

back, the remaining residual material must be activated with ac‐

tivator -D 181 801 A1- .

Caution

Activator must not have contact with paint or the paintwork will

be damaged.

If the window flange has been repaired or partially renewed, the

area concerned must be cleaned and primed again after painting.

1. Flush bonded windows    

275

 

– Apply adhesive material to primed area -1- or to trimmed seal‐

ant bead, holding double cartridge gun -VAS 5237- at right

angle to window.

WARNING

Window must be installed within 10 minutes, or adhesive prop‐

erties of glass adhesive will be impaired.

♦ Using two suction lifters -V.A.G 1344- , install glass pane in

window aperture, align to centre and press in onto spacing lip.

♦ Secure windscreen during curing period with window adjust‐

ers.

♦ It is absolutely necessary to install the plenum chamber cover

as described 

⇒ page 263

 .

♦ Replace stickers (e.g. for airbag) which may be installed.
♦ The activator must not come into contact with the window

heater bus bar.

♦ If the adhesive bead is too thick and the adhesive expands

onto the area of the window heating, excess adhesive must

be removed.

1.20

Minimum curing period

WARNING

Special standards must be adhered to when replacing bonded

windows. One of these standards is, for example, that a freshly

bonded windscreen must comply with the safety requirements,

even in an accident, following the minimum prescribed curing

period.

The minimum curing period for 2K adhesive -DA 004 600 A2- is

three hours for all windows.
Minimum curing period is the time from bonding the window until

vehicle may be used. During this time, the vehicle must stand on

a level surface at room temperature (at least 15 °C).

WARNING

Vehicle is safe to use only after the curing period is completed.

1.21

Touching up paint damage

Paint structure must be restored according to specifications in the

“Paint” workshop manual.
The following repair method is suitable for paint finish damaged

in areas which are not visible:

Painting over twice (wet-on-wet) with glass/paint primer -D

009 200 02- - flash-off time = at least 10 minutes.

276

 

 

 

 

 

 

 

 

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