Volkswagen Front Wheel Drive 1974-1989 Repair Guide

Hatchback Window Glass

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REMOVAL & INSTALLATION



  1. Remove the wiper arm, wiper motor, back door trim and defogger connector.
  2.  
  3. Remove the rear window molding.
  4.  
  5. Use an awl to make a hole in the sealant.
  6.  
  7. Pass a piece of piano wire, about 1 / 8 in. (3mm) in diameter, through the hole, and attach wood bars to both ends.
  8.  
  9. Two people should hold the bars, one inside and one outside the vehicle, and then "saw" the sealant from around the glass, cutting along the border between the glass and the sealant.
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  11. Then, with the help of an assistant, remove the glass from the vehicle. Note the location of the spacers and clips, and make sure that none of them are lost during windshield removal.
  12.  

To install:
  1. Use a knife to smoothly trim the sealant on the body. Leave a layer about 0.04-0.08 in. (1-2mm) thick.
  2.  

If there are small gaps or flakes in the sealant use new sealant to patch it.

  1. Carefully clean and remove any dirt or grease from a 1.97 in. (50mm) wide area around the circumference of the glass and the remaining bond of the body.
  2.  
  3. Bond a dam along the circumference of the glass 0.31 in. (8mm) from the edge.
  4.  

Securely bond the dam and allow it to dry before proceeding to the next step.

  1. Apply primer with a brush to the circumference of the glass and the body, and allow it to naturally dry for 20 to 30 minutes.
  2.  

Be sure not to allow dirt, water, oil, etc. to come in contact with the coated surfaces, and do not touch it with your hand!

  1. Install the spacers in their original positions. Replace any clips with flaws.
  2.  
  3. When the primer has dried, cut the nozzle of the sealant cartridge on an angle, then apply a 0.43 in. (11mm) thick bead of repair seal 0.28 in. (7mm) from the frame of the glass. If necessary, smooth the repair seal to correct any irregularities.
  4.  
  5. Attach the back door glass to the body. Fully lower the side windows to prevent any pressure from being exerted on the back door glass should the doors be closed suddenly. Keep the side windows open until the repair seal dries to some degree.
  6.  
  7. Remove any excess, or add repair seal where necessary.
  8.  
  9. Check the back door glass for water leaks. If a leak is found, wipe off the water and add repair seal.
  10.  
  11. After checking for water leaks, install the molding.
  12.  
  13. Install the wiper arm, wiper motor door trim and defogger connector.
  14.  

 
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