1

2
Overview
Pretreatment of the adhesive bonding
between the window and bodywork
Old window New window
Ceramic layer
Precoated
window
Cut down adhesive
bead
Cleaner
D 009 401 04
Primer D 009 200 02
Activator
AMV 181 800 02
New flange
(Lack)
Old flange
Cleaner
D 009 401 04
Primer D 009 200 02
Cut down
adhesive bead
Apply adhesive
1 component adhesive DH 009 100
2 component adhesive D004 300 05
(Set)
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no
yes yes
no
yes
yes
yes
no
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!
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 (sufcient for at least 15 applications)
Injector
Z 481 280 WE
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1. If the damaged area is located within the
direct eld of view of the driver -1-. This area
is represented by a strip approx. 29 cm in
width (DIN A4 landscape format) in the cen-
tre of the drivers eld of vision in the direc-
tion of travel; the upper and lower limits are
dened by the operating range of the winds-
creen wiper.
2. If cracks originating from the the damaged
area -2- are longer than 50 mm or propagate
outwards 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 lm or the inner glass
pane -4- is damaged.
5. If ingress of moisture and/or dirt into the
lower crack areas -3- has already occurred.
6. If the window has already been damaged for
some 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 eld of vision or at the edge of
the 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 strip
is tinted by means of a dyed intermediate lm.
Can tinted windows or windows with tinted anti-glare strips be repaired,
too?
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1. Loosen up the area of impact using a car-
bide-tipped pin, however take care not
enlarge the damaged area and do not
remove any glass splinters.
2. Extract any moisture from the damaged area
using a vacuum pump, while heating the
damaged area from inside the vehicle using
a blow dryer. If moisture cannot be extracted,
do not attempt to repair the damage.
3. Attach a mirror from the interior of the vehicle
and and align it in such a way that the dama-
ged area can be observed clearly.
4. Attach the tool holder and injector in such a
way that the opening is located exactly above
the point of impact. Using the mirror, check
that the tool holder and injector are positio-
ned correctly.
5. Fill the injector with 2-3 droplets of resin (the
quantity of resin to be used does not depend
on the size of the damaged area). Put the
bottle of resin back into the box straight away,
as the resin is sensitive to UV light. Wait until
the resin ow has reached the rubber seal.
Repair procedure
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Window Repair
6. Tension the injector. The correct pressure is
applied when the point of impact becomes
clear 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 to
prevent it from sliding.
Repeat this process at least 3 times until the
air has been completely displaced from the
damaged 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 is
important to observe the damaged area in
the mirror.
7. Cut off the cover lm and keep it ready.
Remove the injector together with the tool
holder and immediately apply the lm to the
damaged area (do not press it on) in order to
prevent the ingress of air. The lm contains
an activator to cure the resin.
8. Put the injector back into the box again
straight away, as the resin is sensitive to UV
light and can be re-used for the next repair
job. Put the tool holder back into the case in a
stress-relieved state and remove the mirror
together with the holder.
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9. Secure the UV lamp above the damaged
area. Shine the UV lamp on the resin for up
to 10 minutes, then remove the UV lamp .
10. Smooth off the damaged area with the strip-
per blade and, if necessary, subsequently
polish the damaged area using a 12-volt drill
tted 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 tted window was bonded in
place during production or if repairs have already been performed.
In the production process, adhesive is applied by
maschine with the result that the height of the adhesive
bead -1- is normally even.
When the window is inserted, spreading (width -b-) of
the adhesive bead is therefore minimal.
The process of cutting out the window is relatively
simple.
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 dif-
cult.
To cut out a window bonded in place in the production
process, you can use:
Cutting cord 357 853 999
Cutting cord 357 854 955
or Blade V.A.G 1561A
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Several indicators can be used to nd out whether a window has been inserted during produc-
tion or in the course of repair work:


Has adhesive emerged from the window ange 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 nd this out is to check to see if the date of manufacture of the window matches up with
the 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 and
date 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: 1998
Each 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 = December
and 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 of
production of the vehicle, it can be assumed that repairs have been performed.
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Window must be inserted immediately,
otherwise adhesive properties of
adhesive sealing material will be
impaired.
During the curing period, x the window in place
using adhesive tape.
It is advisable to use adhesive remover D 002 000
10 as the cleaning agent.
To clean the plastic trims, allow the adhesive
sealing material to cure for approx. 1 hour and
then pull off the trims.
Materials
1. The materials are stored in box D 004 700.
2. Observe the curing times (see page 13).
3. Only use 2-component adhesive for winds-
creen and side windows.
4. Heating:
Heat 1-component window adhesive DH 009
100, DH 009 100 03 for 20 minutes in cart-
ridge heater V.A.G. 1939.
w 2-component adhesive must not be hae-
ted
5. Small cartridge 110 ml DH 009 100 03 for
sealing and/or when 300 ml cartridge is insuf-
ficient.
DH 009 100
DH 009 100 03
D 004 300 05
AMV 181 800 02
D 009 200 02
D 009 401 04
D 009 500 25
D 002 00010
1-component window adhesive
1-comp. window adhesive (cartridge)
2-component window adhesive
Activator
Glass primer/paint primer
Cleaning solution
Primer applicator
Adhesive remover
Materials
13
During the curing period, the
vehicle must stand on a level sur-
face at room temperature (>15 C) .
Touching up paint damage
The paint structure is to be restored to meet the
specications in the Workshop Manual under
"Vehicle Painting" and, if necessary, anti-corrosion
measures are to be performed as described in the
folder under "Surface Treatment/Chemical
Materials".
If the paintwork is damaged in non-visible areas, apply
two coats of glass/paint primer to the paintwork (wet in
wet).
D 009 200 02 - curing time: approx. 10 minutes.
Cleaning surfaces soiled by adhesive
sealing 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 passenger
cabin of the vehicle, do not push
out on the window inserted
beforehand.
Curing times for
SKODA
Window Adhesive Equipment
Wind-
screen
DH 009 100
without airbag
with airbag
4h
16h
4h
16h
D 004 300 05
without airbag
with airbag
1h
4h
1h
4h
Side win-
dow
DH 009 100 4h 4h 4h
D 004 300 05 1h 1h 1h
Rear
window
DH 009 100 4h 4h 4h 4h 4h
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
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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 cutting
cord), remove burrs at front to prevent
paint 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 be
coated with activator AMV 181 800 02 before app-
lying the adhesive.
Do not prime precoated windows!
Do not allow the activator to come
into contact with the paint, otherwise
the paint will be damaged!
Curing time: 10 minutes
Precoated windows of the models listed below
must be activated with AMV 181 800 02:
Window without PUR precoat
1. Window
2. Precoat
3. Ceramic layer
Windows without PUR precoat have a ceramic
substrate.
Before the adhesive is applied when performing
repairs, the bonding surface must be cleaned with
cleaning solution D 009 401 04 and coated with
Primer 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 ange
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 facing
away from the adhesive plate
Remove the A-pillar trims
Pull the sealing lip off the window ange using the
plastic wedge and spray with cleaning solution D
009 401 04 (lubricant substitute)
Using the small tube -2-, insert the cutting cord -1-
under the sealing lip -3- of the window ange -4- on
all 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 material
towards the vehicle interior. Lay the cutting cord
double as far as the windscreen wiper axis.
Secure outer end of cutting cord to windscreen
wiper axis -1-.
Secure (inner ) end of cutting cord to spooling
device.
Attach spooling device V.A.G. 1654 .
Move the spooling device as shown and cut out
the 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. The
precoat is comprised of items 1, 2 and 3.
Clean the precoat with a dry, non-linting cloth.
Only apply activator AMV 181 800 02 using 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 paint
may 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 ange 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
100 in cartridge heater V.A.G 1939 for 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
1561/10 with 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 lip
using handle -1- and push it through the adhesive
bead (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 window
as possible.
Unscrew the handle and thread the cutting cord
through the eyelet.
Pull in both ends of the cutting cord (use pliers
and wear gloves).
Using the tube -1-, insert the cutting cord in bet-
ween the sealing lip and the window ange (if the
cutting cord breaks, the cutting wire may also be
used).
If the gap dimensions are too narrow, guide the
cutting cord further along the outer edge of the
window and press it under the sealing lip using
the plastic wedge.
Remove side trim
Remove the side support for the luggage area
cover and detach the C-pillar trim.
Pull sealing lip off the window ange
on all sides of the window with the
plastic wedge and spray sealing lip
with 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 spooling
device V.A.G. 1654 and cut window out by moving
the spooling device.
Alternatively, the window can be cut out by hol-
ding one end of the cutting cord tight using the
handle 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 ange on all
sides using the plastic wedge. Cleaning solution
D 009 40104.
Guide the trimming needle under the sealing lip
and push it through the adhesive bead.
Secure the (inner) end of the thread to the spoo-
ling device.
Attach spooling device V.A.G 1654 and cut out the
window.
Unscrew the handle and thread the cutting cord
through the eyelet .
Pull in one end of the cutting cord (use pliers and
wear gloves).
Using the tube, insert the cutting cord between
the sealing lip and window ange .
If the gap dimensions are too narrow, guide the
cutting cord further along the outer edge of the
window and press it under the sealing lip using
the plastic wedge.
Run the cutting cord around the rear window as
shown.
Press the cutting cord in deep enough to avoid
damaging the sealing lip or spacer web.
Secure the outer end of the cutting cord at the
windscreen wiper axis or draw the end of the cut-
ting cord through into the vehicle interior, and
counter-hold with toggle handleV.A.G 1351/1.
Pull off the terminals for the heated rear window
and press the spade terminal tabs onto the
window.
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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
30
Octavia
1. Windscreen
2. Sealing lip
3. Spacer web
4. PUR adhesive sealing material
dimension - a=8mm
dimension - 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 material
dimension - a=8mm
dimension - 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
34
Felicia Fun
Assembly owerview
Rear window
1. Rear window
2. Sealing lip
3. PUR adhesive sealing material
35
Notes
36