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)

    US 2-01

    no

    yes yes

    no

    yes

    yes

    yes

    no

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    3

    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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    4

    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

    US 2-02

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    5

    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:

    US 2-03

    US 2-04

    US 2-05 US 2-06 US 2-07

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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?

    US 2-08

    US 2-09

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    8

    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.

    US 2-13

    US 2-14

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    9

    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!

    US 2-15

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    10

    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

    US 2-16

    US 2-17

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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.

    US 2-18

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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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    14

    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

    US2-19

    US2-20

    US2-21

    US2-22

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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

    US2-23

    US2-24

    US2-25

    US2-26

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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

    US2-27

    US2-28

    US2-29

    US2-30

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    V.A.G 1351

    US2-30

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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

    US2-40

    US2-41

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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)

    US2-50

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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.

    US2-51

    US2-52

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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

    US2-53

    US2-54

    US2-55

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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

    US2-56

    US2-57

    Undamaged window

    US2-58

    US2-59

    US2-60

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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.

    US2-61

    US2-62

    US2-63

    US2-64

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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.

    US2-65

    US2-66

    US2-67

    US2-68

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    Forman

    Assembly overview

    Side window

    1. Side window

    2. Separate cover strip

    3. PUR adhesive sealing material

    US2-70

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    Assembly overview

    Side window

    Felicia Combi

    1. Side window

    2. Sealing lip

    3. PUR adhesive sealing mate-rial

    US2-71

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    1. Glass

    2. PUR adhesive sealing material

    Felicia Pick-Up

    Assembly owerview

    Rear window

    US2-72

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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

    US2-74

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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

    US2-75

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    Octavia Combi

    Assembly owerview

    Rear window

    1. Rear window

    2. Sealing lip

    3. PUR adhesive sealing material

    US2-76

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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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