ssp_002_ru_Ремонт и замена стекол
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Overview
Pretreatment of the adhesive bonding
between the window and bodywork
Old window New window
Ceramic layerPrecoatedwindow
Cut down adhesivebead
CleanerD 009 401 04
Primer D 009 200 02
ActivatorAMV 181 800 02
New flange(Lack)
Old flange
CleanerD 009 401 04
Primer D 009 200 02
Cut downadhesive bead
Apply adhesive
1 component adhesive DH 009 1002 component adhesive D004 300 05
(Set)
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yes yes
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Page
Window Repair 4
Window Replacement 10
Materials 12
Tools 14
Precoats 18
Procedure 20
Forman 26
Felicia Combi 27
Felicia Pick-up 28
Felicia Van plus 29
Octavia 30
Octavia Combi 32
Felicia Fun 34
Contents
This Learning and Practice Book does not substitute Workshop manual!
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Window Repair
Repair kit VAS 1993
Contents:
Tool holder
Mirror
Scriber
Vacuum pump
Transformer
12V power drill
Milling and polishing set
Battery connecting cable
UV lamp
1 set of resin cutters
Film
Resin (sufficient for at least 15 applications)
Injector
Z 481 280 WE
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1. If the damaged area is located within the
direct field of view of the driver -1-. This areais represented by a strip approx. 29 cm inwidth (DIN A4 landscape format) in the cen-tre of the drivers field of vision in the direc-tion of travel; the upper and lower limits aredefined by the operating range of the winds-creen wiper.
2. If cracks originating from the the damagedarea -2- are longer than 50 mm or propagateoutwards towards the edge of the window.
3. If the diameter of the point of impact is grea-ter than 5 mm.
4. If the intermediate film or the inner glasspane -4- is damaged.
5. If ingress of moisture and/or dirt into thelower crack areas -3- has already occurred.
6. If the window has already been damaged forsome time.
When is it not permitted to repair a window?
When is it permitted to repair a window?
The following damage may be repaired if it is not located within the drivers field of vision or at the edge ofthe window:
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Window Repair
Repairs must be performed in an area which is
not exposed to direct sunlight.
The temperature of the area to be repaired
must be roughly the same as that of the
workshop.
The working area must be protected against
ingress of moisture.
Where may repairs be performed?
Only dry-clean the area to be repaired. Use of
cleaning agents is not permitted.
Carefully remove any foreign matter in the area
to be repaired.
How must the area to be repaired be prepared?
Yes, because the window or tinted anti-glare stripis tinted by means of a dyed intermediate film.
Can tinted windows or windows with tinted anti-glare strips be repaired,
too?
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Window Repair
6. Tension the injector. The correct pressure isapplied when the point of impact becomesclear from the centre outwards. Wait 10 minu-tes and then relieve the tension on the injec-tor up to the end of the cutting cord.
When releasing the injector, hold it tight toprevent it from sliding.
Repeat this process at least 3 times until theair has been completely displaced from thedamaged area. As more and more air is dis-placed, the cracks become decreasingly visi-ble.When the injector is tensioned, a pressure of
up to 1,8 MPa is produced.
To avoid cracking the glass any further, it isimportant to observe the damaged area inthe mirror.
7. Cut off the cover film and keep it ready.
Remove the injector together with the toolholder and immediately apply the film to thedamaged area (do not press it on) in order toprevent the ingress of air. The film containsan activator to cure the resin.
8. Put the injector back into the box againstraight away, as the resin is sensitive to UVlight and can be re-used for the next repairjob. Put the tool holder back into the case in astress-relieved state and remove the mirrortogether with the holder.
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9. Secure the UV lamp above the damaged
area. Shine the UV lamp on the resin for upto 10 minutes, then remove the UV lamp .
10. Smooth off the damaged area with the strip-per blade and, if necessary, subsequentlypolish the damaged area using a 12-volt drillfitted with a polishing wheel.
The repair job is completed and the vehicle is again roadworthy!
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Window Replacement
Before cutting out a window, it is advisable to check to see if the fitted window was bonded inplace during production or if repairs have already been performed.
In the production process, adhesive is applied bymaschine with the result that the height of the adhesivebead -1- is normally even.When the window is inserted, spreading (width -b-) ofthe adhesive bead is therefore minimal.
The process of cutting out the window is relativelysimple.
When adhesive is applied with workshop tools, the height -h- of the adhesive bead -1- is uneven.When the window is inserted and pressed down, the surplus adhesive is then spread over a wider area(width -b-).
The process of cutting out the window is more diffi-cult.
To cut out a window bonded in place in the productionprocess, you can use:
Cutting cord 357 853 999Cutting cord 357 854 955
or Blade V.A.G 1561A
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Several indicators can be used to find out whether a window has been inserted during produc-tion or in the course of repair work:
Has adhesive emerged from the window flange in the area of the inner trims?
Are the fastenings of the inner trims damaged or not?
Has the paintwork been touched up in the window opening area?
Have accident repairs which have involved removing the window been performed ?
Another way to find this out is to check to see if the date of manufacture of the window matches up withthe date of production of the vehicle.
An identifying mark is imprinted on the edge of every vehicle window.This mark contains information regarding the manufacturer, compliance with test standards, type anddate of manufacture.
In the lower part of identifying mark, the date of manufacture is coded according to month and year, e.g.:
8 . . . .
This number indicates the year of production:1998Each dot represents a month, where:
6 dots to the left of the year = January
1 dot to the left of the year = June
6 dots to the right of the year = July
1 dot to the right of the year = Decemberand so on.
In the example above, the date of manufacture is September 1998 (8 . . . .).
If there is a large discrepancy between the date of manufacture of the window and the date ofproduction of the vehicle, it can be assumed that repairs have been performed.
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During the curing period, thevehicle must stand on a level sur-face at room temperature (>15 C) .
Touching up paint damageThe paint structure is to be restored to meet thespecifications in the Workshop Manual under"Vehicle Painting" and, if necessary, anti-corrosionmeasures are to be performed as described in thefolder under "Surface Treatment/ChemicalMaterials".
If the paintwork is damaged in non-visible areas, applytwo coats of glass/paint primer to the paintwork (wet inwet).
D 009 200 02 - curing time: approx. 10 minutes.
Cleaning surfaces soiled by adhesivesealing material
First, clean the paint surface using a dry cloth.Remove the remaining adhesive sealing mate-rial using adhesive remover D 002 000 0.
Be sure to follow the applicable safety regulati-
ons when processing these materials.
When cleaning the passengercabin of the vehicle, do not pushout on the window insertedbeforehand.
Curing times for
SKODA
Window Adhesive Equipment
Wind-screen
DH 009 100 without airbagwith airbag
4h
16h
4h
16h
D 004 300 05 without airbagwith airbag
1h
4h
1h
4h
Side win-
dow
DH 009 100 4h 4h 4h
D 004 300 05 1h 1h 1h
Rearwindow
DH 009 100 4h 4h 4h 4h 4h
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Tools
Tools
Spooling device V.A.G 1654 A
Cutting cord 357 853 999
Cutting wire 357 845 955
(not shown)
Multi-purpose cutter V.A.G 1683
Electric cutter V.A.G 1561/A
Blade V.A.G 1561/1
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Blade V.A.G 1561/2
Blade V.A.G 1561/3
Blade V.A.G 1561/7
V.A.G 1351/1
Cutting wire
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Tools
Repair kit V.A.G 1755
w Handle
w Trimming needle
w Small tube (for pulling in the cuttingcord), remove burrs at front to preventpaint damage
w Plastic wedge
Double suction lifters V.A.G 1344
Cartridge gun V.A.G 1628
Cartridge heater V.A.G 1939
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V.A.G 1351
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PUR precoated window
1. Window
2. Precoat
3. Ceramic layer
Precoats
The precoat is comprised of an industrially injec-tion-moulded polyurethane-based (PUR) material.When performing repairs, the precoat must becoated with activator AMV 181 800 02 before app-lying the adhesive.
Do not prime precoated windows!
Do not allow the activator to comeinto contact with the paint, otherwisethe paint will be damaged!
Curing time:10 minutes
Precoated windows of the models listed belowmustbe activated with AMV 181 800 02:
Window without PUR precoat
1. Window
2. Precoat
3. Ceramic layer
Windows without PUR precoat have a ceramicsubstrate.Before the adhesive is applied when performingrepairs, the bonding surface must be cleaned withcleaning solution D 009 401 04and coated withPrimer D 009 200 02.
Windows with a ceramic substrate
must not be activated.
Curing time:10 minutes
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Notes
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1. Cutting cord
2. Small tube
3. Sealing lip
4. Bodyshell window flange
5. Windscreen
6. Adhesive sealing material
7. Eccentric (wedge)
Unclip the roof edging trims in the area of the A-pillars
Unscrew the front wiper arms
Remove the plenum chamber cover
Move eccentric back
Turn the interior rear-view mirror so that it is facingaway from the adhesive plate
Remove the A-pillar trims
Pull the sealing lip off the window flange using theplastic wedge and spray with cleaning solution D009 401 04(lubricant substitute)
Using the small tube -2-, insert the cutting cord -1-under the sealing lip -3- of the window flange -4- onall sides (the cutting wire may also be used)
5. Windscreen
6. Move eccentric (wedge) back
Procedure
Removing and installing (example:
OCTAVIA)
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Using the broach (from V.A.G 1474), pull the cut-ting cord through the adhesive sealing materialtowards the vehicle interior. Lay the cutting corddouble as far as the windscreen wiper axis.
Secure outer end of cutting cord to windscreenwiper axis -1-.
Secure (inner ) end of cutting cord to spoolingdevice.
Attach spooling device V.A.G. 1654.
Move the spooling device as shown and cut outthe window glass.
1
1. Windscreen wiper axis
When cutting out a window, always wear protective goggles and gloves.
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1. Sealing lip
2. Spacer web
3. Area in which adhesive bead is to be applied
4. Glass pane
Installing windscreen
Preparing new window for glazing
New windows are supplied precoated with PUR. Theprecoat is comprised of items 1, 2 and 3.
Clean the precoat with a dry, non-linting cloth.
Only apply activator AMV 181 800 02using applica-tor -1- D 009 500 25(felt ball with wire) to precoat -2- of the window.
Allow activator to cure in air for at least 10 minutes.
The activator must not come into con-tact with the paint, otherwise the paintmay be damaged.
Cut back the residual material to max. 2 mm, e.g.
using scraper V.A.G 1561/8,
The residual material serves as an adhesive base
for the new adhesive sealing material to be applied.
If the window is not bonded immediately after cutting
back the residual adhesive beads, the adhesive
beads must be activated.
The bonding surface should not be pri-
med, activated or treated with cleaning
solution. Keep bonding surface free
from dirt and grease.
max. 2mm
Preparing body flange for glazing
Procedure
1. Applicator
2. Precoat
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Insert window into window opening using two
double suction lifters (V.A.G 1344), align and
press in as far as spacer web.
Fix window in place using eccentric.
Heat the 1-component window adhesive DH 009
100in cartridge heater V.A.G 1939for 20 minutes.
Apply a continuous bead of adhesive material to
the precoat perpendicular to the window.
Window must be inserted immedia-
tely, otherwise adhesive properties of
adhesive sealing material will be
impaired.
Before reusing an undamaged window, cut back
the residual adhesive sealing material -1- to 1 - 2
mm using the electric cutter with blade V.A.G
1561/10with stop roller. Take care not to damage
the precoat and sealing lip with spacer web -2-.
1. Residual adhesive sealing material
2. Spacer web
Installation instructions
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Undamaged window
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Side window
Removing side window
Guide trimming needle -2- under the sealing lipusing handle -1- and push it through the adhesivebead (use side areas).To avoid paint damage, mask the area surround-ing the puncture point with adhesive tape -3-.Hold the trimming needle as close to the windowas possible.Unscrew the handle and thread the cutting cordthrough the eyelet.Pull in both ends of the cutting cord (use pliersand wear gloves).
Using the tube -1-, insert the cutting cord in bet-ween the sealing lip and the window flange (if thecutting cord breaks, the cutting wire may also beused).
If the gap dimensions are too narrow, guide thecutting cord further along the outer edge of thewindow and press it under the sealing lip usingthe plastic wedge.
Remove side trim
Remove the side support for the luggage areacover and detach the C-pillar trim.
Pull sealing lip off the window flangeon all sides of the window with theplastic wedge and spray sealing lipwith cleaning solution D 009 401 04(lubricant substitute).
Procedure
Run the cutting cord around the side window.Secure both ends of the thread in the spoolingdeviceV.A.G. 1654and cut window out by movingthe spooling device.
Alternatively, the window can be cut out by hol-ding one end of the cutting cord tight using thehandle included in Repair kit V.A.G 1755.
Always wear protective goggles and gloves when cutting out a window.
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Removing the rear window
Unscrew the rear wiper arm.
Pull the sealing lip off the window flange on allsides using the plastic wedge. Cleaning solutionD 009 40104.
Guide the trimming needle under the sealing lipand push it through the adhesive bead.
Secure the (inner) end of the thread to the spoo-ling device.
Attach spooling deviceV.A.G 1654and cut out thewindow.
Unscrew the handle and thread the cutting cordthrough the eyelet .
Pull in one end of the cutting cord (use pliers andwear gloves).
Using the tube, insert the cutting cord betweenthe sealing lip and window flange .
If the gap dimensions are too narrow, guide thecutting cord further along the outer edge of thewindow and press it under the sealing lip usingthe plastic wedge.
Run the cutting cord around the rear window asshown.
Press the cutting cord in deep enough to avoiddamaging the sealing lip or spacer web.
Secure the outer end of the cutting cord at thewindscreen wiper axis or draw the end of the cut-ting cord through into the vehicle interior, andcounter-hold with toggle handleV.A.G 1351/1.
Pull off the terminals for the heated rear windowand press the spade terminal tabs onto thewindow.
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Forman
Assembly overview
Side window
1. Side window
2. Separate cover strip
3. PUR adhesive sealing material
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Assembly overview
Side window
Felicia Combi
1. Side window
2. Sealing lip
3. PUR adhesive sealing mate-rial
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1. Glass
2. PUR adhesive sealing material
Felicia Pick-Up
Assembly owerview
Rear window
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Felicia Van Plus
1. Rear eindow
2. Sealing lip
3. PUR adhesive sealing material
Assembly owerview
Rear window
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Octavia
1. Windscreen
2. Sealing lip
3. Spacer web
4. PUR adhesive sealing materialdimension - a=8mmdimension - b=12mm
5. Ceiling
6. Plenum chamber cover
Assembly owerview
Windscreen
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1. Rear window
2. Sealing lip
3. Spacer web
4. PUR adhesive sealing materialdimension - a=8mmdimension - b=12mm
Assembly owerview
Rear window
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Octavia Combi
Assembly owerview
Rear window
1. Rear window
2. Sealing lip
3. PUR adhesive sealing material
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Assembly owerview
Side window
1. Side window
2. Sealing lip
3. PUR adhesive sealing material
4. Decorative strip
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Felicia Fun
Assembly owerview
Rear window
1. Rear window
2. Sealing lip
3. PUR adhesive sealing material
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Notes
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