Preparing for window installation

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NOTE:

If windshield flange was damaged during removal, paint structure should be repaired according to specifications in article, "Vehicle-Paint" and if necessary, corrosion repair measures should be taken according to guidelines in "Surface Technology/Chemical Materials Folder".

For undamaged removed windshield

When reusing an undamaged window, cut back smoothly residual adhesive sealing material on window and flange using electric cutter V.A.G 1561A and scraper V.A.G 1561/8; do not remove completely!
Residual material acts as a base for the new adhesive sealing material.

CAUTION:

Keep adhesive surface free of dirt and grease.
Only cut back adhesive surface shortly before installation.
Do not prime or use a cleaning solution on the adhesive surface.

New window, installing

Clean windshield in adhering area using D 009 401 04 and prime using D 009 200 02 glass/paint primer.

CAUTION:

For this purpose, apply adhesive stopper profile next to distributing wire on new replacement windows.

Applying primer

Fig 1: Applying Primer Evenly In One Pass Using Applicator

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Apply primer - 2 - D 009 200 02 uniformly all around on window, centering by markings, using applicator - 1 - , Part No. D 009 500 25 (felt ball with wire).
This determines the distance to window edge - dimension b -.
Primer width - dimension a - is determined by the markings on window.
Begin application with a fully saturated felt. Air drying time approx. 10 minutes.

CAUTION: Ceramic application on window is not primer! It must be primed before the application of adhesive sealing material!

NOTE:

Do not touch up primer strip until after primer has thoroughly dried.

Fig 2: Dimensions For Application Of Adhesive

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Adhesive bead cross section

1 - Adhesive bead

2 - Primer

3 - Washer

Dimension - a - = 8 ± 2 mm.
Dimension - b - =13.5 ± 1.5 mm.
Dimension c is determined by markings on window