Volkswagen Golf Service & Repair Manual: Removing and installing windscreen

Volkswagen Golf Service & Repair Manual / General body repairs, exterior / Glazing/window mechanism / Windscreen / Removing and installing windscreen

Note

The removal of a bonded window is described using the Removal kit for flush bonded windows -V.A.G 1474 A-.

Alternatively, you can also use the cutting tool for bonded windows -VAS 6452-.

Another alternative is to use the window removal set -VAS 6888-.

Special tools and workshop equipment required

Removal kit for flush bonded windows -V.A.G 1474 A- or Removal kit for flush bonded windows -VAS 6452-

Suction lifter -V.A.G 1344-

Cutting tool -V.A.G 1351-

Windscreen removal kit -V.A.G 1755-

Cartridge gun -V.A.G 1628-

Cartridge heater -V.A.G 1939-

Electric cutter -V.A.G 1561 A-

Cutting blade -V.A.G 1561/2-

Cutting blade -V.A.G 1561/8-

Setting gauge -3371-

Cutting blade -V.A.G 1561/19-

Removing and installing windscreen

Double cartridge gun -VAS 5237-

Removing

–	Remove A-pillar upper trims on left and right → General body repairs, interior; Rep. gr.70.

–	Remove left and right sun visors → General body repairs, interior; Rep. gr.68.

–	Remove interior mirror → General body repairs, interior; Rep. gr.68.

–	For vehicles with front camera for driver assist systems -R242- remove front camera → Electrical system; Rep. gr.96

–	Lower moulded headliner in area of windscreen → General body repairs, interior; Rep. gr.70.

–	Moulded headliner can now be lowered sufficiently to allow windscreen to be cut out without damage occurring to moulded headliner.

–	Removing plenum chamber cover → Chapter.

Removing and installing windscreen

On vehicles with heated windscreen

–	Unscrew hexagon nut -6-, and bond line -5- to windscreen.

–	Disconnect connectors -1 and 3-.

–	Bond lines -2 and 4- to windscreen.

Removing and installing windscreen

–	Slide suitable covering film -V.A.G 1474/8- between windscreen and dash panel.

–	Pull cutting cord -1- through adhesive sealing material into inside of vehicle using awl -V.A.G 1474/2-.

–	Secure inside end of cutting cord against falling out using Pull toggle -V.A.G 1351/1--3-.

–	Insert cutting cord -2- into window flange using tube -1-.

–	Place cutting cord around the front windscreen.

–	Ensure that cutting cord lies under front windscreen in corners.

Removing and installing windscreen

–	Attach the ends of cords -4- on removal kit for flush bonded windows -VAS 6452--1-.

–	Put cutting cord around suction cups of reel device -arrow-.

–	Use plastic wedge -2- to press cutting cord against windscreen while cutting in order to have clearance at window flange and dash panel.

Removing and installing windscreen

–	Position removal kit for flush bonded windows -VAS 6452- at lower corners of windscreen.

–	Change permanently position of left removal kit for flush bonded windows -VAS 6452- from “position I”to “position III” and cut windscreen free.

–	Change permanently position of right removal kit for flush bonded windows -VAS 6452- from “position IV”to “position VI” and cut windscreen free.

–	Use two suction lifters -V.A.G 1344- to lift the windscreen from the vehicle.

Installing

Note

The windscreen as a genuine replacement part is delivered with spacers.

In vehicles without panorama sliding sunroof, the spacers -1- remain installed.

In vehicles with panorama sliding sunroof, the seal -4- must be installed.

Removing and installing windscreen

–	Separate spacers -1- with a suitable tool.

–	Bond seal -4- to edge of windscreen.

–	For vehicles with front camera for driver assist systems -R242- install front camera → Electrical system; Rep. gr.96 and calibrate front camera → Running gear, axles, steering; Rep. gr.44.

–	Preparing old undamaged window for glazing → Chapter.

–	Preparing new window for glazing → Chapter.

–	Preparing body flange for glazing → Chapter.

–	Installation instructions → Chapter

–	Minimum curing period → Chapter

Removing broken windscreen

Removal of a broken windscreen is performed in the same manner as the removal a broken rear window → Chapter.

Assembly overview - windscreen

1 - Windscreen Removing and installing → Chapter 2 - PUR adhesive sealant Cross section of bead: -width b- = 7 m ...

Rear window

...

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