Bonded Windshields - Removing/Installing
87VW1Applies To JETTA
(from 1985 M..Y.)
Group
64
Subject Windshield
Part Identifier 6414
Key Points Bonded windshields
^ Removing/installing
^ Replacing
Supercedes Product Circular, Group 64, 85-02 H 001
Number
87-02
April 28, 1987
Bonded windshield, removing
Tools required
^ Cutting tools for glass, VW 1351
Obtainable locally:
utility knife pliers cutting wire (piano wire), 0.5 mm (0.20 in.) dia. or approx. 24 American Wire Gauge, 14-16 in. length needle nose pliers heat gun
Work sequence
- remove both windshield wiper arms
- remove A-pillar trim moldings
- remove inside rear view mirror
WARNING
Wear protective goggles and leather gloves when removing and installing glass.
CAUTION
Attach masking tape to body around entire windshield perimeter to protect paint.
1 glass 2 rubber seal 3 exterior molding 4 adhesive sealant 5 interior beading
Note
Take care not to damage paint around windshield perimeter when removing exterior molding.
- remove exterior molding 3 and rubber seal 2 with needle nose pliers
- with aid of helper push wire 6 through adhesive sealant 4 between glass 1 and interior beading
5. Grab wire on outside with needle nose pliers.
- attach ends of wire to tool VW 1351 (or use two needle nose Vise Grips (R)), so part X is inside and part Y outside car. Thread wire through in direction of arrows and secure ends at screws A and B.
- push point of tool X (or inside Vise Grips (R)) into adhesive approx. 152 mm (6 in.) from point where wire was originally passed through
CAUTION
Adhesives used in bonded windshield installations, original or replacement, may give off toxic fumes when heated. Read container labels. Ensure adequate ventilation.
- heat windshield with heat gun in area to be cut to soften adhesive
- pull tool Y (outside Vise Grips (R)) evenly in direction B until it reaches anchor point Z
- repeat process and cut window free all around
- remove interior beading
- carefully lift out windshield
Bonded windshield (used), installing
Parts required Part number Quantity
interior beading 165 898 778 1
exterior beading 165 853 299A 01C 1
(with rubber seal)
repair kit D 004 300 03 1
adhesive cartridge D 009 100 03 1
caulking gun obtain commercially 1
CAUTION
Part numbers are listed for reference only. Always consult with your Parts Department for the latest information.
CAUTION
Interior beading and exterior molding must always be replaced when reinstalling a used windshield.
Work sequence
CAUTION
Do not remove adhesive completely. It is used as a base for new adhesive material.
If body parts in area of glass flange are being worked on or replaced, flange must be recleaned and primed after painting. (Use paint primer supplied in repair kit.)
- using utility knife, cut remaining adhesive material on body flange smooth
- Do not remove adhesive completely
- apply cleaning solvent from repair kit to windshield and body flange
- install rubber seal 2 to windshield glass 1
- install exterior molding 3 into rubber seal
Note
Ceramic black-out band around windshield is not primer. Before applying adhesive sealing compound, prime this area with primer supplied in repair kit.
- cut applicator head for required primer width
^ a = 15 mm (19/32 in.).
- apply primer evenly all around edge of windshield and rubber seal (as shown) in one continuous operation. Make sure applicator head is always completely saturated.
1 glass (shown for reference only)
4 adhesive sealing compound
5 interior beading
- install interior beading 5 to body flange
- apply adhesive sealing compound 4 around entire flange
- bonding sealing compound should be applied in shape shown (in mm), which is determined by nozzle opening and rate of application
- place four spacers (made from rubber wedges) onto windshield body flange
^ use 3M (R) Window Sealer or equivalent to hold wedges in place
^ put one wedge on each side, one wedge on top and bottom
- with helper, hold glass and place into windshield opening
^ wedges help to center glass
CAUTION
Open windows while bonding/sealing compound is hardening to prevent excess pressure on glass when doors are closed.
Hardening of adhesive sealing compound
- vehicle must stand at least three hours (previously 24), at room temperature of 20~C (68~F) and relative humidity of 65-70% before allowing vehicle to be driven
- keeping sealed/bonded area wet will promote hardening process
- Excess adhesive sealing compound can be removed using a cleaning solvent such as supplied in repair kit
^ do not use cleaners which contain alcohol
- to clean plastic trim, let adhesive sealing compound harden 2-3 hours, then scrape off excess with plastic wedge
CAUTION
Avoid putting pressure on glass from inside car when cleaning around glass while bonding/ sealing compound is hardening.
Labor operation code: 64 14 21 0 Time allowance diagnosis: N/A repair: 235.00 T.U. quality check: 10.00 T.U. total: 245.00 T.U.
New bonded windshield, installing
^ new windshields are now supplied with external molding, rubber seal, and a pre-bonded seal attached (as shown)
Note
All removing or installing procedures remain identical except the following:
^ interior beading must still be replaced
^ priming windshield is no longer required
^ before installing windshield, clean pre-bonded seal with a cleaning solvent such as supplied in repair kit