• Electric cutter - SAT 1561A-
• Knife set - SAT 1561/20-
• Separator for windows - VAS 6452- 18)
• Release lever - U 30800-
• Measuring tool - U 40807-
• Window suction pads - VAG 1344-

Special tools and workshop equipment required

• Window sealant pistol - SAT 5350-
• Cable holder knob - VAG 1351/1-
• Removal equipment - VAG 1474B-
• Window extraction kit - VAG 1755-
• Cartridge heater - VAG 1939A-
• Dual component window sealant - VAS 5237-

Materials

• Cutting wire
• Cutting cord
• 1 component glue 19) 21)
• Dual component glue  20)
• Actuator for washers
• Cleaning solution
• Applicator
• Adhesive remover
• Primer (glass/paint)

18) Note the manufacturer's instructions in the packaging insert slip.
19) To apply this material use the window sealant pistol - SAT 5350- .
20) To apply this material use the window glue pistol - SAT 5360- .
21) Note drying times.

Undamaged side window, 3-door model: removal

• Loosen and secure upper covers B-pillar and C-pillar.
• Remove side panel.

• To remove the side window on the model 3-door, use the splitter - VAG 1474B- with two steering rollers and cutting wire.
• Use wire reel - VAS 6452/1- to reel off about 2.50 metres of cutting wire (corresponding to 2 turns) and cut off.

• Protect the vicinity of the working area and the body surface around the reamer exit point with body tape -2- and with the protective film on the separating fixture - VAG 1474B- .

• Cut through the surrounding profile -1- with the plastic wedge, cutting from surface of body beside the reamer exit point.

• Prick through the bead of adhesive sealant (PUR) with a bradawl -3- from the inside to the outside at the top left-hand corner of the glass exactly above the attachment block -arrow a-.
• Pierce the adhesive bead once again using another awl -3- from the inside to the outside at the bottom left-hand corner of the window exactly below the securing block -Arrow b-.
• Lace both ends of the cutting wire -5- into the awl -3-. Pull on the awl and guide the ends of the thread in the passenger compartment.

Note

• Note that the ends of the thread need to be sufficiently long to reach the top right edge of the window.
• To ease insertion of the cutting cord, spray the window's surrounding profile with soapy water.

• Using the fixture -4- on the window removal kit - VAG 1755- , position the cutting thread -5- under the surrounding profile of the window.
• As shown on the figure, secure the reeling fixture of the window removal kit - VAG 1755- by attaching suckers to the inside surface of the window.
• Guide both ends of the cutting thread -1- into the rollers -2- on the reeling fixture of the cutting fixture for windows - VAS 6452- .

Note

• During the cutting process, use the reamer whenever the cutting thread is near to the edges of the body panel.
• In this process, the retaining blocks -arrows- should be retained.

• With the aid of the reel device of the window splitter - VAS 6452- , cut off the adhesive bead in the zones defined by dimensions -a- and -b-.
• Release the thread in a controlled manner using the rollers on the reeling fixture, then move the reeling fixture into its new position as shown in this Fig.

Note

• During the cutting process, use the reamer whenever the cutting thread is near to the edges of the body panel.
• In this process, the retaining block -Arrow- should be retained.

• With the aid of the reel device, cut off the adhesive bead at the zones defined by dimensions -a- and -b-.
• Release the thread in a controlled manner using the rollers on the reeling fixture and remove the reeling fixture from the window.
• With the wire unrolling device - VAS 6452/1- , unroll approx. 1.50 m of cutting wire (this equates to one complete turn of the wire unrolling device) and cut to length.
• Protect the body surface area near the exit point of the reamer -2- with body tape.

• Cut through the surrounding profile -1- with the plastic wedge, cutting from surface of body beside the reamer exit point.
• Feed the bradawl -2-, from the inside to the outside, via the cut set in the adhesive, in the top left corner of the window, just below the attachment block -arrow a-.
• Push another awl -2- through the cut-off adhesive bead from the inside to the outside at the left-hand bottom corner of the window - exactly above the securing block -arrow b-.
• Guide the two ends of the cutting thread through the aperture in reamer -2-. Pull on the awl and guide the ends of the thread in the passenger compartment.

Note

• Note that the ends of the thread need to be sufficiently long to reach the top right edge of the window.
• To ease insertion of the cutting cord, spray the window's surrounding profile with soapy water.

• Using the fixture -1- on the window removal kit - VAG 1755- , position the cutting thread -2- under the surrounding profile of the window.
• As shown on the figure, secure the reeling fixture of the window removal kit - VAG 1755- by attaching suckers to the inside surface of the window.
• Guide both ends of cutting thread -2- into the rollers of the reeling fixture on the separating fixture for windows - VAS 6452- .

Note

• During the cutting process, use the reamer whenever the cutting thread is near to the edges of the body panel.
• In this process the cutting thread ends cross each other.
• In this process, the retaining blocks -arrows- should be retained.

• By applying the coil guide -arrow- cut the adhesive bead in the area of the dimension -a-.
• Release the thread in a controlled manner using the rollers on the reeling fixture and remove the reeling fixture from the window.
• Move the suction lifter - VAG 1344- onto the outside face of the window and hold the window pressed down against the body flange. Press the tab onto the attachment blocks -b- and -c-, in order to loosen the window from the body.

Note The retaining block -a- is not secured to the body; it is only there for positioning purposes.

• Remove windscreen with the suction filters - VAG 1344- .

Damaged side window, 3-door model: removal

Special tools and workshop equipment required

• Protective goggles and leather gloves
• Loosen and secure upper covers B-pillar and C-pillar.
• Remove side panel.

• To remove a damaged side window on the 3-door model, use the electric knife - SAT 1561A- and the set of blades - SAT 1561/20-

• Protect the chassis and the interior from the glass remains -1-.
• Remove the pieces of glass as far as the adhesive bead.
• Using the electric knife - SAT 1561A- and the set of blades - SAT 1561/20- cut off the adhesive bead stuck to the body flange.

Install side window, 3-door model: removal

Note Follow the instructions accordingly.