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Removing and Installing Windscreen



Removing And Installing Windscreen









Preliminary work
Removing cowl panel cover. Refer to Removing and installing cowl panel cover -removing
Remove A-post trim. Refer to Removing and installing A-post trim - removing
Remove cover for instrument panel (defroster cover). Refer to Removing and installing cover for instrument panel (defroster cover)
Remove interior rearview mirror. Refer to Removing and installing the interior rearview mirror - removing
Disconnect plug for aerial amplifier. Refer to Removing and installing aerial amplifier

General warning notes
- General information on installing and removing car windows

Tools and materials
The following tools and materials are required for removing and installing the windscreen with 2-component adhesive:









Removing windscreen

Removing spacer blocks
1. Insert a spatula under the spacer blocks -1- and remove the expanding rivets. Spacer blocks -1- must be replaced.






Removing windscreen

NOTE: The door windows must not be closed until after the curing time has elapsed.

1. Lower the door windows.
2. Remove windscreen with the cutting wire separator. Refer to General information on installing and removing car windows






Preparing window frame for installation

Removing adhesive from the body

NOTE: The surface coating of adhesive residue on the window aperture of the body acts as an adhesive base for new bonding material. Keep cut surfaces clean and free of grease and do not clean with cleaning solution.

1. When removing remaining adhesive -2- with the cutting tool -C- and the flashing knife -D- on the body, ensure that a surface coating of adhesive remains -3-.






Cleaning and priming areas that are free of adhesive residue or have paint damage or where there is newly built-up paint in the window aperture of the body

NOTE: A flash-off time of at least 2 minutes must be observed between the cleaning of the window aperture and the application of the primer. No cleaning solution residues must remain on the body.

1. Clean areas that are free of adhesive residue or have new paint or where there is damage to the top coat paint in the non-visible area of the window aperture in the body with cleaning solution -H1- and touch up with primers -H2-.






Preparing windscreen for installation

Removing windscreen seal

NOTE: Only if the windscreen is re-installed

1. Pull off the seal -4-. Remove adhesive residues with cleaning solution -H1-.






Removing adhesive from the windscreen

NOTE:
- Only if the windscreen is re-installed
- The remaining adhesive helps new adhesive to stick. Keep cut surfaces clean and free of grease and do not clean with cleaning solution.

1. Equip cutting device -C- with the flashing knife -D- and remove the remaining adhesive from the windscreen, ensuring that a surface coating of adhesive remains.






Fitting windscreen seal
1. Stick seal -4- to the windscreen -5- from one edge along the entire border.






Marking the bonding area

NOTE: Only if the windscreen is new and does not have a preliminary coat

1. Before applying the adhesive, mark the course of the adhesive bead in accordance with the dimensions -E- = 160 mm, -F- = 30 mm on the left and right on the lower edge of the windscreen.






Activating the bonding section of the windscreen

NOTE: Only if the windscreen is re-installed

1. During long idle periods (] 24 hours) apply activator -H3- to the remaining adhesive.






Priming the windscreen

NOTE:
- Only with new windscreens
- A ventilation period of at least 2 minutes must be observed between the cleaning of the glass and the application of the primer. No cleaning solution residues may remain on the body.

1. Clean the windscreen with cleaning solution -H1-.
2. Apply primer -H2- to the glass flange in the area of the marking.






Installing windscreen

Preliminary work before windscreen installation

NOTE: The removed windscreen can be reinstalled if there was no prior damage to the windscreen and the windscreen was removed without damage.

1. Clip in spacer blocks and press in body-bound rivets.
2. Installing cover for instrument panel (defroster cover). Refer to Removing and installing cover for instrument panel (defroster cover) - installing

Fitting windscreen into the body

NOTE:
- Two persons are needed to insert and adjust the windscreen.
- Owing to the bonding section, the windscreen can no longer be aligned on the seal because the section immediately adheres to the windscreen when inserted.

1. Apply suction cups -B- to the windscreen -5- and insert the windscreen into the window aperture. Press the windscreen -5- up as far as it will go. When doing so, press the lower edge of the glass against the spacer blocks. Mark the windscreen with adhesive tape -6- and remove.






Preparing 2-component adhesive for processing

NOTE:
- The adhesive has an open time of -15 min-, which means that the bonding material must be applied and the car window must be assembled within this period of time.
- In order to ensure that the substance is completely mixed, apply a 30 mm long adhesive bead of fresh adhesive to a piece of cardboard before processing.






1. Preparing 2-component adhesive for processing. Refer to Processing of Porsche 2-component window bonding agents

Applying adhesive to the windscreen

NOTE: When applying the adhesive, it is essential to ensure that the adhesive bead overlaps by approx. 30 mm at the beginning and at the end.

1. Using the bonding gun -A-, apply 2-component adhesive to the windscreen along the seal -4- in the form of a triangular bead measuring -X= ca. 15 mm- -Y= ca. 8 mm-.






Pulling off protective film

NOTE: Make sure that no further work is performed in the area of the seal once the protective film has been removed.

1. Before bonding the windscreen, remove the protective film from the seal such that no residues remain.

Inserting windscreen into the body

CAUTION: Danger of material damage if specified curing time of adhesive is not observed.
- There will not be a proper adhesive bond if the prescribed curing time of the adhesive is not observed.

- The vehicle must not be used until the curing time has elapsed.
- Curing time: 3 hours
- Temperature: at least 10 °C
- Fixing time: approx. 1 hour

NOTE:
- Two persons are needed to insert and adjust the windscreen.
- The rear window can no longer be aligned, because the bonding section on the seal immediately sticks to the body when the rear window is installed.

1. Guide the windscreen -5- into the window aperture and insert in the pre-marked positions.






Cleaning fields of vision

NOTE: The door windows must not be closed until after the curing time has elapsed.

1. Adhesive which has oozed out must be removed immediately and the affected fields of vision must be cleaned using cleaning agent -H1-.

Subsequent work

Reworking
1. Install cowl panel cover. Refer to Removing and installing cowl panel cover - removing
2. Connect plug for aerial amplifier. Refer to Removing and installing aerial amplifier
3. Install A-pillar trim. Refer to and installing A-post trim - installing

NOTE: Only with new windscreens

4. Bonding on the interior rearview mirror. Refer to Securing the interior rearview mirror

NOTE: The interior rear-view mirror may only be installed after a curing time of three hours.

5. Installing the interior rearview mirror. Refer to Removing and installing the interior rearview mirror - installing
6. Closing door windows.
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