2012 Volkswagen Eos

Windshield removal and replacement instructions
By Bob Beranek
February 28, 2012
AUTO

Vehicle type: Two-door convertible

NAGS® numbers*:  At press time, a number had not yet been assigned

Watch for: This convertible is unique in that the windows, sunroof, back glass and trunk are all interrelated and must be calibrated using the dealer’s diagnostic system.  All parts except the windshield and front door glasses should be referred to a dealer for calibration.

Also note that the windshield on this vehicle has an exposed edge; the wall and floor of the pinchweld are exposed and visible. The new glass does not have a PAAS or underside molding so no special low-conductive urethane or special bonding procedures are necessary.  Normal urethane products can be used.

 *With permission from National Auto Glass Specifications. Call NAGS at 800/551-4012 or visit http://glass.mitchell.com/.

A. Windshield

Preparation

1. Cover the front seats, floorboards, dash and steering wheel with a clean drop cloth or disposable plastic covers. Note: Always wear eye and hand protection when working with glass. Make sure you have the right glass and moldings and that the urethane systems you are about to use are current.

 2. Drape the fender with a fender cover and tape up any vulnerable areas on the vehicle to protect against possible damage. Tape up the defroster vents to prevent debris from falling into the openings.

 3. Remove the rearview mirror by giving it a quarter turn.
 

 4. Remove the windshield-wiper nut covers.

 5. Remove the windshield-wiper nuts using a 14-millimeter wrench or socket.

 6. Remove the hood bulb weatherstrip by pulling off the front part of the fire wall.  Set aside.
 

 7. Starting in one of the lower corners, separate the cowl panel from the lower cowl retainer by prying it upwards and then following it along the entire bottom of the glass.              

 8. The top and sides of the windshield have an exposed edge; there is no PAAS or underside molding.   Note: Before beginning windshield removal, verify the new windshield is the correct one and the urethanes and primers are current. Never use outdated products as this could jeopardize the structural integrity of the vehicle and the safety of its passengers.    
   

Removal

9. Make sure cutting blades are sufficiently sharp.

 10. Remove contaminants from the glass and pinchweld to prevent contact with the urethane. Because the glass is a truly exposed edge mounting, it is recommended that you measure and record the gap between the glass and pinchweld wall so you can replicate it during the installation process.

11. There are no gravity stops, so preparations must be made for holding the glass in place until the urethane cures.

12. The exposed edge is far enough away from the pinchweld wall to cut out the windshield using a cold knife, but it is highly recommended that you tape up the perimeter of the pinchweld wall. If scratches occur, they will be visible. Also tape the defroster vents.

13. Use the cutting tools of your choice to remove the glass from the adhesive bead.  The pinchweld wall and floor are exposed, so take care to avoid scratches during cutout.

14. Take the windshield out of the opening using vacuum cups. Make sure the vacuum cups do not overlap a crack in the glass. Lift the glass and place it on a windshield stand or suitable workstation.

Installation

15. After cutting the windshield out, remove contaminants such as dirt, moisture and debris from the pinchweld. Clean the dashboard.

16. Dry fit the new glass to the opening. Mark your glass using a grease pencil or retention molding tape.

17. Place your vacuum cups on the new windshield in the appropriate location.

18. Set the windshield onto the old urethane.

19. With the windshield resting in the opening, make sure it is in the right spot.

20. Adjust both sides to the correct setting, marking the passenger side, then the driver side. Lift the glass and place it on a windshield stand or suitable workstation.

21. Follow the urethane manufacturer’s recommendations for installation. The new glass does not have a PAAS or underside molding so no special low-conductive urethane or special bonding procedures are necessary.  Normal urethane products can be used.

22. Clean the inside of the windshield using a urethane manufacturer-recommended product. Do not touch the bonding area of the windshield after cleaning, prepping or priming it.

23. Wear powder-free Nitrile gloves to protect against harsh chemicals.

24. Apply the glass prep and primer following the urethane manufacturer’s instructions.

25. Using the tool of your choice, remove the original urethane bead, leaving 1-2 mm of urethane on the pinchweld. Make sure there are no contaminants and do not touch the pinchweld after you have prepped the area.

26. Apply the pinchweld primer only to the areas where needed, and follow the urethane manufacturer’s recommendations. Allow preps and primers to dry as recommended by the urethane manufacturer.

27. Apply a triangular bead of urethane to the same path as the freshly cut urethane on the pinchweld. Before cutting your V-notch, cut the tip off of your nozzle with a nozzle-cutter. With the cut nozzle, measure to the top of the roofline, and at 1/16-inch higher than the roofline, make a mark on the nozzle with a pen or marker. Notch the nozzle up to the marked line; this will give you the appropriate triangular bead.

28. Lift the windshield from the windshield stand or workstation using vacuum cups. Set the windshield on the urethane at the mark you made during your dry fit. Lower the driver’s side of the windshield onto the urethane and line it up with the dry-fit mark; it is now in place.

29. The windshield is now ready to be decked. Press firmly to ensure a good seal.

30. Before re-installing the parts, check for leaks. Use a leak detector to go over the perimeter of the windshield. If you find a leak, apply more pressure or add more urethane to the spot and ensure that the glass makes contact with the wet urethane.

31. Re-install the removed parts in reverse order.
 

32. Make sure to remove the shipping strip from the lower cowl panel retainer before attempting to insert the cowl.

33. Allow the urethane to cure according to the urethane manufacturer’s recommended cure time before returning the vehicle to the customer. Warning: Disregarding the safe drive-away time that your urethane manufacturer recommends could jeopardize the structural integrity of the vehicle and the safety of its passengers.

34. You have completed the removal and replacement of the windshield.

© 2012 National Glass Association. All rights reserved. Visit GlassMagazine.com for glass removal and replacement instructions for more than 450 vehicles. To sign up to receive the For Technicians Only e-bulletin, email FTO@glass.org.

The author is president of Automotive Glass Consultants in Sun Prairie, Wis. Write him at bob@autoglassconsultants.com.