Back Window Glass: Service and Repair
WM 648619 Removing and installing rear window
Technical values
Preliminary work
1. Remove wiper motor for rear window washer. -> 923419 Removing and installing wiper motor for rear window washer - section on "Removing" 923419 Removing and installing wiper motor for rear window washer
2. Remove additional brake light. -> 947019 Removing and installing additional brake light - section on "Removing" Service and Repair
3. Remove trim panel for tailgate. (Only for vehicles without rear window washer) -> 709219 Removing and installing trim panel for tailgate - section on "Removing" Service and Repair
Technical values
Gap dimensions of rear window
=> Gap dimension: 3 mm+0.5 mm-0.5 mm
Gap dimension
=> Gap dimension: 6 mm
Gap dimension
=> Gap dimension: 4 mm+1 mm-0.5 mm
Gap dimension
=> Gap dimension: 3 mm+1 mm-1 mm
Gap dimension
=> Gap dimension: 3 mm+0.5 mm-0.5 mm
Gap dimension
=> Gap dimension: 9 mm+0.5 mm-1.5 mm
Gap dimension
Tools and materials
The following tools and materials are required for removing and installing the rear window with 2-component adhesive:
Removing rear window
Installation position of rear window
Information
- The procedure for removing car windows is described in => Removing glass with cutting wire separator.
1. Extend the spoiler.
2. Switch off ignition and disconnect remote control.
3. Affix adhesive tape -1- from the lower left corner of the rear window to the rear lid.
Preparing rear window
4. Secure electric connectors (from the rear window to the rear lid).
4.1. Disconnect electric connectors -2-.
Disconnecting plug connections
4.2. Affix electric connectors securely to the rear window using adhesive tape -1-.
Affixing plug connections securely
5. Secure electric connectors (from the rear lid to the rear window).
5.1. Disconnect electric connectors.
5.2. Affix electric connectors securely to the rear lid using adhesive tape -1-.
Affixing plug connections securely
6. Remove grommet for wiper motor for rear window washer.
WARNING
Vehicle windows removed and installed incorrectly
- Danger of cuts
- Risk of eye injuries
-> Wear personal protective gear.
-> Always shut off power supply when replacing cutting knife.
7. Apply a bead of adhesive from inside out in the area protected by the adhesive tape using the scratch awl.
Preparing rear window
Information
- Make sure not to damage the heated rear window connections when removing the glass with the cutting wire.
- Cut up to just before the connection.
- Slacken the cutting wire.
- Guide the cutting wire past the connection on the inside.
Guiding cutting wire past electric connection
- Counter with an awl.
Countering with an awl
- Make sure that the cutting wire does not press against the electric connection when separating the glass.
- Continue separating the window glass.
8. Remove rear window with the cutting-wire separating device.
Preparing window aperture for installation
Preparing window aperture for re-installation
1. Remove adhesive on the body.
Information
- The surface coating of adhesive residue helps new adhesive to stick. Keep cut surfaces clean and free of grease and do not clean with cleaning solution.
1.1. When removing remaining adhesive with the cutting tool -C- and flashing knife -D- on the body, ensure that a surface coating of adhesive remains.
Removing adhesive residue on rear lid
2. Clean and prime paint damage or newly built-up paint areas in the window aperture of the body.
Eliminating paint damage
2.1. Clean new paint areas or 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 primer -H2-.
Information
- A ventilation period of at least 10 minutes must be observed between the cleaning of the glass section and the application of the primer! No cleaning solution residues may remain on the body.
Preparing rear window for installation
Preparing rear window for installation (re-installation only)
Information
- The removed rear window can be reinstalled if there was no prior damage to the rear window and the rear window was removed without damage.
1. Remove adhesive from the rear window.
Removing adhesive from rear window
1.1. Fit cutter -C- with the flashing knife -D- and remove remaining adhesive from the rear window, ensuring that a surface coating of adhesive remains.
Information
- The remaining adhesive helps new adhesive to stick. Keep cut surfaces clean and free of grease and do not clean with cleaning solution.
2. Apply activator to the bonding section of the rear window.
2.1. During long idle periods, apply activator -H3- to the remaining adhesive.
Preparing rear window for installation (new rear window)
1. Clean and prime the window.
Cleaning and priming window
1.1. Clean the window glass with cleaning solution -H1-.
1.2. Apply primer -H2- to the glass flange in the area of the marking.
Information
- A ventilation period of at least 10 minutes must be observed between the cleaning of the glass and the application of primer! No cleaning solution residues may remain on the windscreen.
Installing rear window
CAUTION
Danger of material damage if specified curing time of adhesive is not observed! In order to ensure that the bonded joint is sufficiently strong, the following boundary conditions must be adhered to:
- 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
->
Information
- The removed rear window can be reinstalled if there was no prior damage to the rear window and the rear window was removed without damage.
Information
- Check stop bits.
- Replace damaged or missing stop bits.
1. Prepare 2-component bonding material for processing. -> 6X00IN Processing of Porsche 2-component window adhesive
Information
- 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.
2. Apply adhesive to the rear window.
2.1. Using a bonding gun -A- apply 2-component adhesive to the rear window along the precoating or on the primer in the form of a triangular bead measuring -X = approx. 15 mm-.
Information
- 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.
Information
- Two persons are needed to insert, position and secure the rear window.
3. Insert the rear window into the body.
Inserting rear window
3.1. Apply suction cups to the rear window and insert the rear window into the window aperture. Fit the rear window at the upper edge and position the lower rim.
4. Adjust the rear window gaps.
4.1. Set gap dimension by moving the rear window. -> 648619 Removing and installing rear window - section on "Technical values"
4.2. Secure upper edge of rear window to the rear lid with adhesive tape -1- to prevent it from slipping.
Securing rear window
5. Clean the fields of vision.
Removing adhesive compound
5.1. Adhesive that has oozed out must be removed immediately and the affected fields of vision must be cleaned using cleaning agent -H1-.
Subsequent work
1. Install wiper motor for rear window washer. -> 923419 Removing and installing wiper motor for rear window washer - section on "Installing" 923419 Removing and installing wiper motor for rear window washer
2. Install additional brake light. -> 947019 Removing and installing additional brake light - section on "Installing" Service and Repair
3. Install trim panel for tailgate. (Only for vehicles without rear window washer) -> 709219 Removing and installing trim panel for tailgate - section on "Installing" Service and Repair