Windshield - Removing and Installing
83VW02Applies To
RABBIT/PICKUP
1983 Models
Group
64
Subject:
Windshield
Part Identifier 64 12
Key Points
Removing/installing
(Supersedes Product Circular, Group 64, No.. 83-02, 3/15/83) C
Number
83-04
September 21, 1983
Bonded windshield, removing/installing
Work sequence
Removing
WARNING
Protective goggles and leather gloves must be worn when removing and installing glass. Also read warnings supplied with installation kit
- read through entire work sequence before starting repair
- remove windshield wiper arms and radio antenna
- attach masking tape all around windshield frame to protect paint
- starting at corner of windshield, pull trim molding out and away from windshield with needle nose pliers
- warm plastic molding along windshield with hot air gun and pull out from window frame until completely removed
- remove inside rear view mirror and "A" pillar trim on left and right sides
- remove header trim above windshield
- with aid of helper, push wire (about 350-400 mm or 14-16 in.. long) through urethane sealant from inside to outside and grab wire on outside with long-nose pliers
Note
Cutting wire, mentioned above, is available locally as piano wire, 0.5 mm (.020-.024 in.)
- attach ends of wire to tool VW 1351 (or use 2 needle nose vise grips) so part X is inside and part Y outside of car. Thread wire through in direction of arrows and secure ends at screws A and B
- push point of tool X (or inside vise grip) into urethane approx. 152 mm (6 in.) down from point where wire was originally passed through urethane
- heat windshield with hot air gun in area to be cut to soften urethane
- pull tool Y (outside vise grip) down evenly in direction B until it reaches anchor point Z
Note
When tool 1351 (or vise grip) is properly used, part X (inside vise grip) will act as an anchor point for cutting wire and handle Y (outside vise grip) will be used to pull wire down to anchor point so it knifes smoothly through urethane. Do not use sawing motion. Periodically reheat windshield with hot air gun in area to be cut, to ease cutting action
- remove tool X (inside tool) from present anchor position and reinsert into urethane approx. 152 mm (6 in.) further down along windshield
- pull down again on handle Y (outside tool) and cut through urethane until new anchor point is reached
- continue procedure until entire windshield has been cut free
- remove window glass
Installing
Note
Primer/urethane are available from Parts Dept. as kit, Part No. 175 898 099
- cut away enough old urethane (with heat knife, warmed putty knife, etc.) around glass (if to be reused) and window frame to give smooth uniform surface Note Area must be clean and free of grease. It is not necessary to remove all old urethane
- install molding A with seam positioned at bottom center of windshield
- clean ceramic black-out band on windshield with clear primer No. 1. Wipe primer on and wipe off immediately, using cheesecloth
CAUTION
Do not wipe primers onto trim molding or else urethane will stick to molding (arrow, below). This will cause difficulty if molding is to be removed during future repairs
- apply black-out primer No. 2 and allow to dry for min. of 10 minutes. Use dabber supplied in kit. Do not extend primer beyond width of ceramic black-out band on glass
Note
Do not confuse black-out band installed on windshield with black-out primer No. 2. Band on windshield is not primer. All steps of procedure must still be followed
- cut tip of nozzle so it will form shape of bead shown
- apply bead of urethane to primed area of blackout band. Use caulking gun
- install windshield into vehicle (2 mechanics required) using vacuum cup holders (obtain locally)
- push down all along molding until seated
- water test for leaks immediately
- allow one hour for urethane to cure before driving car
CAUTION
When cleaning around windshield inside car, avoid putting pressure on glass while urethane is hardening
- reinstall windshield wipers, radio antenna, rear view mirror and inside trim moldings
- install windshield into vehicle (2 mechanics required) using vacuum cup holders (obtain locally)
- push down all along molding until seated
- water test for leaks immediately
- allow one hour for urethane to cure before driving car
CAUTION
Avoid putting pressure on glass from inside car when cleaning around glass while urethane is hardening.
- reinstall windshield wipers, radio antenna, rear view mirror and inside trim moldings