Body repairs – exterior · Glazing · Windscreen

Removing and installing windscreen

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-
Hand-cartridge gun - V.A.G 1628-
Cartridge heater - V.A.G 1939-

Removing

Remove A-pillar trim ⇒ General body repairs, interior; Rep. gr. 70; Trims, interior; Removing and installing A-pillar trim.
Remove all sun visors ⇒ General body repairs, interior; Rep. gr. 68; Equipment; Removing and installing sun visor.
Remove interior mirror ⇒ General body repairs, interior; Rep. gr. 68; Interior mirror; Removing and installing interior mirror.
Moulded headliner can now be lowered sufficiently to allow windscreen to be cut out without damage occurring to moulded headliner.
For vehicles with rain sensor ⇒ Electrical system; Rep. gr. 92; Windscreen wiper system; Removing and installing rain and light sensor
Removing plenum chamber cover ⇒ 3.5 Removing and installing plenum chamber cover.
Remove water deflector of Polo Blue Motion ⇒ 3.11 Removing and installing water deflector.

Slide protective backing - V.A.G 1474/8- -1- between front windscreen and dash panel.
Pull one end of cutting cord -2- through adhesive sealant into vehicle interior 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 all around the window glass.
Ensure that cutting cord lies under window in corners.
Pull the 2nd end of cutting cord through the adhesive sealant.

Secure the 2nd end of cord to reel device - V.A.G 1654 A-.
Attach the winding device - V.A.G 1654 A- at “position I”.
Turn reel device - V.A.G 1654 A- accordingly and cut windscreen glass free.
Use plastic wedge to press cutting cord against windscreen glass while cutting in order to have a certain amount of clearance between window flange and dash panel.

Installing