Volkswagen ID.3: General information, Body. Glass repair

• Introduction
• Preparing glass repair
• Carrying out glass repair

Introduction

Introduction

General information

Laminated glass windows are composed of 2 glass panes joined by a transparent plastic film. During the manufacture of laminated glass less strain builds up, which means that in the event of damage there are barely any small fragments. In addition, damaged laminated glass panes provide a better visibility.

Glass repairs have the following advantages over renewing:

♦ Less expensive solution

♦ Less time-consuming process

♦ Less environmental impact

♦ Ingress of air or water, corrosion, poor reception in vehicles with windscreen aerials can be avoided

Tinted, heated or vapourised glass panes, windscreens with sun protection strips and heat-reflecting glass can be repaired. The tint of the plastic interlayer is retained.

Types of damage

Types of damage to laminated glass that can be repaired under the specified conditions:

Cow's eye (stone chip)

Star-shaped fracture (stone chip)

Important

● Cracks starting from the impact point must not be longer than 50 mm.

● Cracks must not end in the windscreen seal.

Combined fracture (stone chip)

Important

● Cracks starting from the impact point must not be longer than 50 mm.

● Cracks must not end in the windscreen seal.

Daisy (stone chip)

Half moon (stone chip)

Crack (scratch)

Important

● No dirt or moisture must have penetrated into the inner area of the crack.

● Cracks with an impact point may be repaired.

Cracks without an impact point may have occurred due to internal strain in the material.

Prerequisites

Impact point

a - Ceramic band

A - Repair area

B - Field of view

1 - Window

Important

● Windows -1- may be repaired if damage on the outside and inside are not in the same point.

● The impact point must be in repair area -A-.

The field of vision -B- corresponds to a strip centred on the centre of the steering wheel and bounded at the top and bottom by the windscreen wiper field.

Size

Important

● Diameter -a- of the impact point must be ≤ 5 mm.

When the impact point is larger, the vacuum and pressure cycles cannot be carried out properly.

The larger the impact point, the larger the visual marks may be after the repair.

Important

● The interior of the repair area must be visually inspected.

● Customers must be informed of possible negative effects or reasons if a glass repair cannot be carried out.

Soiling

Important

● If existing dirt is not removed, dirt may still be visible after the glass repair.

Moisture

Important

● To determine moisture inside, the damage must be viewed from all possible angles.

● If a dark area becomes lighter when the viewing angle is changed, there may be moisture inside the defect.

● A glass repair must only be carried out if the moisture has been eliminated.

Discolouration

Important

● Liquids such as window washer fluid or acid rain can react with the plastic film in the damaged area and cause a shadow, usually bluish. Shadows may be visible after the glass repair.

Delamination

Delamination is the detachment of the glass pane from the plastic film as a result of the impact.

In the event of delamination, very bright spots are visible in the damaged area.

Important

● Damage where the inner plastic film is intact may be repaired.

All vehicles (continued)

If the film compresses and deforms during repair, dark spots are visible after the glass repair.

Preparing glass repair

Preparing glass repair

Special tools and workshop equipment required

♦ window repair kit -VAS 6092-

Evaluation

– Evaluate whether a glass repair is economically, aesthetically and technically feasible → Rep. gr.52; Introduction.

Preparing tool

– Make sure that the components of the window repair kit -VAS 6092- are in proper condition.

– Check expiry date of any required materials.

Preparing vehicle

Important

● The vehicle must not be exposed to direct sunlight during the glass repair, especially if the glass repair is carried out outdoors.

● The work area must be protected from moisture.

– Cover vehicle areas that can be damaged during glass repair.

Carrying out glass repair

Carrying out glass repair

Removing

– Clean the repair area with a dry cleaning cloth, while protecting the repair area from further soiling.

– Remove loose fragments or surface contamination from the repair area with a carbide pin -A-.

Important

● Do not increase the diameter.

– Wet the suction cup of mirror -A- with gel.

– Position mirror -A- on the inside so that the repair area is clearly visible.

If the impact point diameter is too small:

Note

If the diameter of the impact point is too small, the resin cannot penetrate.

– Drill out the impact point with a commercially available drill and a suitable drill bit at 2-second intervals.

Note

If drilling is done in short intervals, overheating of the drill bit can be avoided.

Continued

– View the repair area from different angles.

Important

● If a dark area appears to be getting lighter, it is most likely moisture.

If moisture has entered the repair area:

– Extract moisture.

– Use vacuum procedure with tool carrier and injector for this.

– Slowly heat inside of repair area with a commercially available hot air blower.

Note

Heat expands the repair area and moisture can escape.

– Allow repair area to cool down.

If moisture cannot be removed:

– Abort glass repair.

Note

Moisture in the repair area can cause damage during and after the glass repair.

– Inform the customer.

– Renew window → General body repairs, exterior; Rep. gr.64; Windscreen; Removing and installing windscreen.

Continued

– Slowly heat inside of repair area with a commercially available hot air blower.

Note

Sudden temperature changes can cause further damage to the repair area.

– Wet the suction cup of tool carrier -A- with gel.

– Position tool carrier -A- centrally to the impact point and push lever towards rear.

– Open packaging.

– Remove injector -B- and resin -A-.

– Loosen piston of injector -B- by 4 to 5 mm.

– Fill resin -A- into injector -B-.

– Stow unused resin -A- in opaque packaging to avoid exposure to UV radiation.

– Screw injector -B- into tool carrier -A- until injector -B- rests lightly against the window.

– Use mirror to centre seal of injector -B- on repair area, and turn until area between window and cylinder is tight.

– Screw in piston -B- until seal stretches by distance -a-.

Important

● When screwing in piston -B-, counterhold cylinder.

● Position of tool carrier -A- must be maintained.

– Allow resin to penetrate for 5 min.

Note

When the damage is of type cow's eye, the resin penetrates quickly.

Note

In the event of closed fractures such as star-shaped fractures, the resin needs more time to penetrate. Only in the case of closed fractures may the piston be pressed lightly to favour the penetration of resin into the damaged area.

Important

● If too much pressure is applied to the repair area, the damage may be enlarged or resin flowers may form between the glass panes and the plastic film.

Vehicles without coloured or insulating plastic film on the inside of the window

If air venting is to be facilitated during the pressure cycle:

Important

● Repair area must have cooled down before pressure is applied.

Note

Heat expands the repair area and makes the resin thinner.

– Slowly heat inside of repair area with a commercially available hot air blower.

Note

Sudden temperature changes can cause further damage to the repair area.

All vehicles (continued)

– Loosen piston -B- until distance -a- has been attained, and leave it in this position for 5 min.

Dimension -a- = 10 mm

Important

● When loosening piston -B-, counterhold cylinder.

Note

Air from inside the repair area is extracted. In the mirror, the air can be observed in the form of small black dots moving towards the injector and gradually disappearing.

– Make sure that the repair area is filled with resin.

– Use mirror to view repair area from all angles.

Important

● The inspection must take place during the vacuum cycle, as air can compress during the pressure cycle and would not be visible as black dots.

– Repeat procedures until the repair area is filled with resin.

Note

At least 2 pressure cycle and 2 vacuum cycles should be carried out.

– To prevent the resin from retracting, perform pressure cycle as the last cycle.

– Cut curing film -A- to size.

Important

● Dimensions should be 4 cm to 5 cm.

– Pull up lever of tool carrier, and slowly pull off the suction cup of tool carrier.

Important

● Air must have been extracted from repair area.

– Place curing film -A- over repair area.

Important

● Do not apply pressure to the repair area to prevent air from entering.

– Remove excess resin outside the curing film -A-.

– Lift curing film -A- and apply a drop -arrow- of finish resin -B- directly to repair area.

– Place curing film -A- again.

– Moisten suction cups of UV lamp -1- with gel.

– Position UV lamp -1- centrally relative to repair area.

– Switch on UV lamp -1-.

Note

The UV lamp -1- has a timer and switches off automatically.

– Allow resin to cure for 5 min. to 6 min.

– Remove mirror.

– Remove UV lamp and curing film.

– Scrape off excess resin -arrow- with a commercially available blade -A- perpendicular to the glass pane.

If there is not enough resin in impact point:

– Apply another drop of finishing resin.

– Place curing film.

– Switch on UV lamp.

– Allow resin to cure.

– Scrape off excess resin with a commercially available blade perpendicular to the glass pane.

Continued

– Clean repair area with lint-free cleaning cloth.

– Clamp felt -B- in commercially available drill -A-.

– Apply a small amount of polish to felt -B-.

– Polish repair area briefly and press on felt only slightly.

– Screw piston into cylinder to stop.

– Store injector in opaque packaging to avoid exposure to UV radiation.

– Clean window from the outside and inside.

Note

The vehicle is operational right after the glass repair, without any waiting time.

General information, Body. General notes – windowsGeneral information, Body. Use of adhesives