Volkswagen Jetta / Jetta Hybrid. Manual - part 49

♦ Cutting blade -

V.A.G 1561/2-

♦ Cutting blade -

V.A.G 1561/8-

♦ Assembly tool set -T10237-
♦ Cutting blade -

V.A.G 1561/19-

♦ Double cartridge gun -

VAS 5237-

1.2

Materials

♦ 2K glass adhesive

DA 004 600 A2 

1

 

2

 

3)

♦ 1K glass adhesive

DH 009 100 A2 

1)

 

2)

 

4)

 

5)

♦ Activator

D 181 801 A1 

1)

♦ Glass primer/paint primer

D 009 200 02 

1)

♦ Cleaning solution

D 009 401 04 

1)

♦ Primer applicator

D 009 500 25 

1)

♦ Adhesive remover

D 002 000 10 

1)

♦ Cutting cord

357 853 999 A

1)

 Observe instructions for use on the information sheet provided

by the manufacturer.

2)

 Observe minimum curing period 

⇒ page 203

 .

3)

 Double cartridge gun -VAS 5237- must be used to apply these

materials.

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1. Flush bonded windows    

193

 

heater -V.A.G 1939- .

5)

 Small cartridge, 180 ml, for sealing and/or when a 400 ml dou‐

ble cartridge alone is not sufficient.

1.3

Repairing windscreen

Note

♦

If windscreen is damaged, determine whether glass can be

repaired before replacing.

♦

Damaged windscreens can be repaired with the window repair

kit -VAS 6092- .

♦

This damage must not exceed a certain size or position.

♦

Each window repair kit comes with a set of instructions.

Special tools and workshop equipment required
♦ Window repair kit -VAS 6092-

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1 - Windscreen

❑ Removing 

⇒ page 195

❑ Installing 

⇒ page 197

 .

2 - PUR adhesive sealant

❑ Cross section of bead:

-width b- = 7.5 mm,

-height a- = 12 mm (in‐

cluding precoating, re‐

sidual material on win‐

dow glass and window

flange).

❑ Minimum curing period

⇒ page 203

 .

3 - Body flange

❑ Touch up paintwork

damage 

⇒ page 203

 .

4 - Gap

❑ Must be uniform on left

and right

5 - Gap

❑ Must be uniform

6 - Windscreen adjuster

❑ 443 845 631 A

7 - Windscreen seal

❑ Is part of windscreen.

8 - Plenum chamber cover

❑ Must be removed from

windscreen seal by

hand only.

❑ Removing and installing

⇒ page 17

9 - Adhesive bead butt end

❑ The butt end of the adhesive bead should be located here.

1.5

Removing windscreen

Carry out following work:
– Remove A-pillar upper trims on left and right ⇒  General body

moving A-pillar trim .

– Removing left and right sun visors ⇒  General body repairs,

interior; Rep. gr.  68 ; Compartments, covers and trims; Re‐

moving and installing sun visor .

gr.  68 ; Interior mirror

– Remove moulded headliner in area of windscreen ⇒  General

body repairs, interior; Rep. gr.  70 ; Roof trim .

– Moulded headliner can now be lowered sufficiently to allow

windscreen to be cut out without damage occurring to moulded

headliner.

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1. Flush bonded windows    

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 .

– Removing plenum chamber cover 

⇒ page 17

 .

– Slide protective backing -V.A.G 1474/8- -1- between front

windscreen and dash panel.

– Pull cutting cord -2- through adhesive sealing material into in‐

side of vehicle 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 around the front windscreen.
– Ensure that cutting cord lies under front windscreen in corners.

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