Volkswagen Front Wheel Drive 1974-1989 Repair Guide

Windshield

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Bonded windshields require special tools and procedures. For this reason, we recommend that all removal, installation and repair work be referred to a qualified technician or body shop.

REMOVAL & INSTALLATION



Special tool set 431 898 099A is required to perform this procedure. You will also need VW glass cutting tool 1351, double suction pad holders for holding the glass, and a caulking gun for applying the bonding/sealing compound.

  1. Remove the rear view mirror, sun visors, front pillar trim, and front header trim.
  2.  
  3. Remove the wiper arms and cowl grille.
  4.  
  5. Remove the front window molding.
  6.  
  7. Remove the glass by separating the glass from the sealant with a power or manually operated remover tool, or use the following procedure:
    1. Use an awl to make a hole in the sealant.
    2.  
    3. Pass a piece of piano wire, about 1/8 in. (3mm) in diameter, through the hole, and attach wood bars to both ends.
    4.  
    5. While two people hold the bars (one inside and one outside the vehicle), "saw" the sealant from around the glass, cutting along the border between the glass and the sealant.
    6.  
    7. With the help of an assistant, remove the glass from the vehicle. Make sure that no spacers or clips are lost during windshield removal.
    8.  

  8.  

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 0.20 in. (5mm) from the edge. Securely bond the dam and allow it to dry before proceeding to the next step.
  4.  
  5. Apply primer with a brush to the circumference of the glass and the body, and allow it to dry for 20 to 30 minutes.
  6.  

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.
  2.  
  3. When the primer has dried, apply a 0.43 in. (11mm) thick bead of repair seal 0.28 in. (7mm) from the frame of the glass using a sealant gun. If necessary, smooth the repair seal to correct any irregularities.
  4.  
  5. Place the windshield into the frame. Fully lower the side windows to prevent any pressure from being exerted on the windshield should the doors be closed suddenly. Keep the door glass open until the repair seal dries.
  6.  
  7. Remove any excess, or add repair seal where necessary.
  8.  
  9. Check the windshield for water leaks. If a leak is found, wipe off the water and apply more repair seal.
  10.  
  11. After the repair seal has dried and water tightness has been confirmed, mount the pillar garnish, cowl panel, cowl grille, wipers, etc.
  12.  
  13. Attach the front header trim, sun visor, interior mirror, etc.
  14.  

 
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