Effect Of Differing Adhesive Quantities:

EFFECT OF DIFFERING ADHESIVE QUANTITIES

Insufficient adhesive:	Excessive adhesive:
Windshield positioned too low in body cutout	Windshield positioned too high in body cutout
Stresses may occur (risk of broken windshield)	Wind noise may occur

Shape of glue bead:

7⁺¹ mm.
11^-2 mm.
CAUTION: Apply adhesive bead swiftly (and uniformly) and install windshield. Maximum skin formation time of adhesive is 10 minutes.
Maintain distance (X) to edge of windshield, refer to measurement (A) to (C) in next work step.

Fig 1: Identifying Shape Of Glue Bead

Maintain the distance (A) of the upper glue bead to the gasket, (B) at side and (C) bottom along the windshield edge.

1 mm.
2 mm.
4 mm.

Uniformly apply cement beads in corners of seal at top and at break in sealing lip.

Fig 2: Applying Cement Beads In Corners Of Seal

NOTE: Adhesive area for plastic adhesive tapes (1) must be free of grease and dust.

Attach two yellow plastic adhesive tapes (1) (Tesa) to roof at a distance (A) from outer corners.

Length: 400 mm.

Width: 50 mm.

250 mm.

Fig 3: Attaching Two Yellow Plastic Adhesive Tapes

Switch on vacuum pump.

Firmly attach special tool 51 9 002 to outside of windshield in center in upper third.

Fig 4: Attaching Special Tool 51 9 002 To Outside Of Windshield

CAUTION: Follow operating instructions for special tool 51 9 002. The pointer of the vacuum gauge must be in the green area. Do not shorten connecting hose between suction hoist and vacuum pump (minimum length 5 m). Replacement with original hose only.

Fig 5: Identifying Pointer Of The Vacuum Gauge

Lift windshield with special tool 51 9 002 over body cutout.

Fig 6: Lifting Windshield With Special Tool 51 9 002

First position windshield carefully at top and align sides evenly.

Lower windshield at bottom and in so doing press upwards on left and right with two special tools 51 3 010 until seal contacts roof uniformly.

Secure windshield (1) in this position on top with yellow plastic adhesive tapes (2) and press down all around.

Fig 7: Securing Windshield (1) On Top With Yellow Plastic Adhesive Tapes (2) And Pressing Down All Around

Switch off vacuum pump.

Remove special tools 51 3 010 and 51 9 002.

To avoid wind noises: The windshield is pretensioned at the top.

Pretension is created with special tool 51 3 130 (three HR foam blocks).

1 piece (1): 40 x 70 x 70 mm (W x H x D).

2 pieces (2): 40 x 30 x 70 mm (W x H x D).

Position of HR foam blocks:

HR foam blocks (1), middle, at distance (A) from top.

HR foam blocks (2), distance (A) from top, distance (B) at side.

100 mm.
Open both front doors.

Fig 8: Identifying Foam Blocks

Secure HR foam blocks (2) with yellow plastic adhesive tape (1) (Tesa).

Pretension windshield with yellow plastic adhesive tape (1) until it is correctly positioned at top.

NOTE: Do not stick yellow plastic adhesive tape (1) above A-pillar finisher (3) or ITS head airbag.

Fig 9: Pretensioning Windshield With Yellow Plastic

CAUTION: Hardened glue can only be removed by machine. Remove contamination caused by residual adhesive immediately with Sika remover 208. Do not press out windscreen glass again for this purpose.

Assemble car.

After hardening time, remove support.

NOTE: Leaks are detected by spraying water under the sealing lips or by using an ultrasonic leak tester and can then be sealed with an appropriate nozzle.