64-1

Windows, removing and

installing
Tools and materials, overview
New windows
Supplied pre-coated with PUR adhesive, parts -1-, -2- and -31 - Sealing lip
2 - Spacing lip
3 - Area for application of cement bead
4 - Window glass

Tools
VAG1654 winding device
Cutting thread 357 853 999
Cutting wire 357 845 955 (not shown)
CAUTION!
Part numbers are listed for reference only. Always check with your Parts
department for the latest information.

64-2

VAG1561 electric cutter

VAG1561/10 blade with stop roller
For cutting down adhesive material on window glass.
VAG1561/8 scraping blade
For cutting down adhesive material on window flange.

VAG1755 repair kit

1 - Handle
2 - Trimming needle
3 - Tube (for pulling in cutting thread or cutting wire)
4 - Plastic wedge
Note:
Handle -1- and trimming needle -2- are commercially available tools.

64-3

VAG1628 cartridge gun

VAG1344 double suction cup

Cartridge heater VAG1939

64-4

Bonded windows, removing and

installing
Tools and materials
Cartridge heater VAG1939
1K- Adhesive........DH 009 100 2), 4)
1K- Adhesive........DH 009 100 03 2), 4), 5)
2K- Adhesive........D 004 300 05 2), 3)
Activator........AMV 181 800 02 1)
Glass primer/paint primer......D 009 200 02 1)
Cleaning solution........D 009 401 04 1)
Primer-applicator........D 009 500 25 1)
Adhesive remover........D 002 000 10 1)
1)

Materials are stored in the box D 004 700.

2)

Note curing time

3)

Only use for windshield and side glass.

page 64-21 .

4)

Heat according to manufactures specifications

with cartridge heater VAG1939.
5)

Small cartridge 110 ml (for sealing or if the 300

ml cartridge is insufficient).
CAUTION!
Part numbers are listed for reference only.
Always check with your Parts department for
the latest information.

64-5

Bonded windshield, assembly overview

1 - Windshield
Removing
Installing

page 64-6
page 64-8

2 - Ceramic layer
3 - Sealing lip
Component part of pre-coating
4 - PUR adhesive sealant
Cross-section of bead:
Width: 7 mm (0.28 in.)
Height: 11 mm (0.43 in.) (including pre-coating,
residual material on window glass and flange)
5 - Molded headliner
6 - Rear-view mirror mounting plate
PUR adhesive
7 - Eccentric
To adjust window gap at top
8 - Window gap

Gap a- = 4 mm (0.157 in.)

64-6

Bonded windshield, removing

WARNING!
Always wear protective goggles and leather
gloves when removing and installing
windshield.
- Unclip roof molding strips in A-pillar area.
- Remove front wiper arms (M8 hex nuts).
Tightening torque: 20 Nm (15 ft lb)
- Loosen screws -1- several turns (relieving tension from clip) and remove with
clip.
- Remove seal -3- and remove plenum cover -4-.
- Turn eccentric counterclockwise set back from glass.
- Twist to remove inside rear-view mirror from adhesive plate.
- Remove sun visors (this provides clearance between window flange and molded
headlining).
- Remove trim from A-pillars

page 70-23 .

- Loosen sealing lip from window flange and spray in cleaning solution D 009 401
04 (as substitute for lubricant).

- Place cutting thread in window flange with help of tube (from VAG1755) (cutting
wire may also be used).

64-7

- Pull cutting thread through adhesive sealing material into inside of vehicle with
broach (from VAG1474). Cutting thread is double up to windshield wiper shaft

- Secure outer end of thread to windshield wiper shaft.

- Secure inner end of thread to winding device.
- Attach VAG1654 winding device in position -I-.
- Move winding device to position -II-, position -III- and so on as necessary, and
cut out windshield glass.
- Press cutting thread against window glass using plastic wedge during cutting
process, in order to have access at window flange and instrument panel.

64-8

Bonded windshield, installing

Preparing old window for re-installation
64-17
Preparing new window for installation
64-18

page
page

Preparing body flange for window installation

page 64-19
Installation instructions
Curing time

page 64-20

page 64-21

64-9

Bonded rear window, assembly overview

1 - Rear window
Removing (window unbroken)

page 64-10

Removing and installing (window broken)

64-12

page

2 - Ceramic layer
3 - Sealing lip (component part of pre-coating)
4 - PUR adhesive sealant
Cross section of bead
Width = 7 mm (0.28 in.)
Height = 12 mm (0.47 in.) (including pre-coating,
residual material on window glass and flange)

64-10

Bonded rear window unbroken,

removing
WARNING!
Always wear protective goggles and leather
gloves when removing and installing
windshield.
- Remove rear wiper arm (M8 hexagon nut).
Tightening torque: 15 Nm (11 ft lb)
- With plastic wedge loosen sealing lip from
window flange all around, and spray in cleaning
solution D 009 401 04 (as substitute for
lubricant).
- With help of handle -1-, guide trimming needle -2- under sealing lip and puncture
through adhesive bead (use side areas).
Note:
The trimming needle must be guided as close to the window as possible (do not
damage heater element).
- Remove handle and pass cutting thread through eye of needle.

- Pull cutting thread towards inside (use pliers and gloves).

- Guide cutting thread between sealing lip and window flange with help of tube -3(cutting wire may also be used).
- If gap is too small, guide cutting thread on outside and push under lip with a
plastic wedge.

64-11

- Place cutting thread around rear window as shown.

Note:
Press in cutting thread deep enough in order to avoid damaging the sealing lip
and/or spacing lip.
- Secure outer end of thread to window wiper shaft, or pull end of thread toward
inside and counterhold with VAG1351/1 pulling handle.
- Disconnect electrical connectors for heated rear window and press connecting
terminals onto window
- Cover inside of window flange -3- with fabric-reinforced adhesive tape.
- Secure inner end of thread on winding device.
- Attach VAG1654 winding device in position -I-.
- Move winding device to position -II-, position -III- and so on as necessary and cut
out window glass.
- Press cutting thread against window glass using plastic wedge during cutting
process, in order to have clearance at window flange.

64-12

Bonded rear window broken, removing

and installing
WARNING!
Always wear protective goggles and leather
gloves.
- Protect body and interior against damage from glass splinters.
- Remove as many pieces of glass as possible, up to adhesive sealing material.
- Disconnect electrical connectors for heated rear window.
- Cover flange -2- with fabric-reinforced adhesive tape.
- Cut through adhesive sealing material (with remaining pieces of glass) in window
opening with electric cutter and VAG1661/10 blade (with stop roller).
Installing
Preparing used window for re-installation
Preparing new window for installation

page 64-17

page 64-18

Preparing body flange for window installation

Installation instructions
Curing time

page 64-20

Page 64-21

page 64-19

64-13

Bonded side window, assembly overview

1 - Side window
Removing (window unbroken)
Removing (window broken)
Installing

page 64-14
page 64-12

page 64-16

2 - Ceramic layer
3 - Sealing lip (component part of pre-coating)
4 - PUR adhesive sealant
Cross section of bead
Width = 7 mm (0.28 in.)
Height = 12 mm (0.47 in.) (including pre-coating,
residual material on window glass and flange)
5 - Retaining clips

64-14

Bonded side window, removing

WARNING!
Always wear protective goggles and leather
gloves.
Removing unbroken window
- Remove side trim

page 70-34 .

- Remove side support for luggage compartment

cover
page 70-36 .
- Loosen C-pillar trim

page 70-28 .

- Insert plastic wedge between sealing lip and

window flange.
- Loosen sealing lip from window flange all around
and spray in cleaning solution D 009 401 04 (as
substitute for lubricant).
- With help of handle -1-, guide trimming needle -2- under sealing lip and puncture
through adhesive bead.

Note:
The trimming needle must be guided as close as possible to the window.

64-15

- Remove handle and pass cutting thread through

eye of needle.
- Pull cutting thread toward inside (use pliers and
gloves).
- Guide cutting thread between lip and window flange with help from tube -1-.
If cutting thread should break, cutting wire can also be used.
- If gap is too small, guide cutting thread on outside and press under lip with a
plastic wedge.
- Place cutting thread around side window.

- Secure outer end of thread on door latch striker pin (apply layer of fabricreinforced adhesive tape along thread path to protect finish).
- Secure inner end of thread on VAG1654 winding device and cut out window by
moving winding device as necessary.
- Press cutting thread against window glass with plastic wedge during cutting
process, in order to have access at window flange.

64-16

Removing broken window

Refer to the procedure for removing a broken
rear window page 64-12
Installing
Preparing old window for re-installation
64-17
Preparing new window for installation
64-18

page
page

Preparing body flange for window installation

page 64-19
Installing instructions
Curing time

pages 64-20

page 64-21

64-17

Window (used), preparing for

installation
Note:
When installing an undamaged window, cut back the remaining adhesive sealing
material -1- to thickness of 1 to 2 mm (0.04 - 0.08 in.) using an electric cutter and
VAG1561/10 blade with stop roller. Do not damage the pre-coating or the sealing
lip with spacing lip -2-.

- Do not damage spacing lip -1- or ceramic layer -2-.

CAUTION!
Do not prime adhesive surface, do not activate and do not treat with
cleaning agent.
Keep adhesive surface clean and free of grease.
Note:
If the window is not installed (bonded) immediately after cutting back the old

adhesive material, it must be activated before installation

page 64-18 .

64-18

Window (new), preparing for installation

New windows are supplied pre-coated with PUR adhesive, parts -1-, -2- and -3-.
1 - Sealing lip
2 - Spacing lip
3 - Area for application of adhesive bead
4 - Window glass
- Rub down pre-coating using dry cloth that is not fluffy.
CAUTION!
DO NOT prime pre-coating and do not treat with cleaning agent.
Keep adhesive surface clean and free of grease.
- Apply thin coat of activator AMV 181 800 01 only on window pre-coating -2using applicator -1- (D 009 500 25 felt ball with wire).
- Allow activator to air dry for at least 10 minutes.
CAUTION!
Activator must NOT have contact with paint, otherwise the paint finish will be
damaged.

64-19

Window flange (body), preparing for

window installation
- Cut back remaining material on window flange using VAG1561/8 scraping blade,
but do not remove it completely.
Notes:
The remaining material is required as a base for better adhesion of the new
coat of adhesive sealing material to be applied. Keep dirt and grease off
adhesive surfaces.
If the window is not installed (bonded) immediately after cutting back the old
adhesive material, it must be activated before installation.
If the window flange has been repaired or partially replaced, the affected area
must be cleaned and primed again after painting.
CAUTION!
Do not prime the adhesive surface, do not activate and do not treat with a
cleaning solution.
Keep the adhesive surface free of dirt and grease.
Activator must NOT have contact with paint, otherwise the paint finish will
be damaged.

64-20

Window installation instructions

Note:
The 1K window adhesive DH 009 100 must be
heated in VAG1939 cartridge heater for 20
minutes.
- Apply adhesive material to pre-coating -1- all around at right angle to window.
CAUTION!
The glass panes must be installed within 10 minutes of the adhesion
application or the adhesion properties will be affected.
Part numbers are listed for reference only. Always check with your Parts
department for the latest information.
- With help of two double suction cups (VAG1344 or equivalent) install glass pane,
center it in window opening, and press in onto spacing lip.
- Hold window glass in position with adhesive tape during curing process.
CAUTION!
If the adhesive bead has been applied too thick and the adhesive expands
onto the area of the window heater, then the excess adhesive must be
removed
page 64-29 .

64-21

Curing time
Curing time: From the installation of the glass
until the vehicle is ready for operation.
During curing time the vehicle must be parked
on a level surface at room temperature, above
15 C (59 F).
Note:
The specified curing time is based on the use of
adhesives and sealants specified by Volkswagen
Window
Windshield

Side

Vehicle

Adhesive

Curing
time

without
airbag

DH 009
100 / 03

4 hours

with
airbag

DH 009
100 / 03

16
hours

without
airbag

D 004 300
05

1 hour

with
airbag

D 004 300
05

4 hours

DH 009

4 hours

window

100 / 03
D 004 300
05

Rear
window

DH 009
100 / 03

4 hours

WARNING!
Vehicle is only safe to drive after curing time
is completed.

64-22

CAUTION!
ALWAYS follow the manufacturer's
instructions for the adhesive/sealing material
being used to install window glass.
Part numbers are listed for reference only.
Always check with your Parts department for
the latest information.

64-23

Door window regulator, removing and

installing
Door window, removing

page 57-10

- Remove cable clip (arrow).

- Loosen hex-head screws -1- and -2-.
- Lift window regulator slightly so that hex-head screws -1- can be pulled through
installation openings.
- Pull window regulator out downward through installation opening.
- Install in reverse order of removal.
Tightening torque (screws -2-): 10 Nm (7 ft lb)