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

...

Other materials:

Removing and installing voltage regulator, manufacturer: Bosch
Special tools and workshop equipment required Offset screwdriver for slotted-head screws -VAS 6416- Torque screwdriver -V.A.G 16 ...

Repairing rain and light sensor, TRW
The housings for the rain and light sensors -G397- from various manufacturers differ. The sensor housing with lens unit is always supplied as a replacement part in separate parts with retaining clips. In vehicles which do not require the ...

Removing and installing inner door cover
Special tools and workshop equipment required Note Removal and installation are described only for the left cover. The right side is similar. Removing ...