Volkswagen Golf / Golf GTI / Jetta. Manual — part 702

- Fold down - arrow - center sun visor - 1 - .

- Remove screw - 2 - out of roof sidemember - 3 - and
remove sun visor.

- Insert protective foil - 1 - V.A.G1474/8 between windshield
and instrument panel.

- Loosen sealing lip in upper area of windshield using a
plastic wedge and spray in Cleaning solution D 009 401 04
(as a substitute for lubricant).

- Insert cutting cord - 2 - into window flange using small
tube.

- For very narrow gap dimensions, guide cutting cord from
outside and press under lip using plastic wedge.

- Push cutting cord end through adhesive sealant into
vehicle interior using awl (from V.A.G1474A ).

Note:

Flush-bonded windows

13/2/2005

In side area of window, guide awl through adhesive sealant
as close as possible to window flange on body, so as not to
damage sealing lip.

- Secure one cord end to Spooling tool V.A.G 1654 A .

- Pull through second cord inward and attach grip from
V.A.G1351 to counterhold.

- Set Spooling tool V.A.G1654 into "Position I" .

- Move spooling tool according to position required and cut
windshield free.

- While cutting free, press cutting cord against window
using plastic wedge in order to have clearance from
window flange and instrument cluster.

Windshield, installing

Preparing undamaged window for glazing

64-1,

Preparing undamaged window for glazing

.

Preparing new window for glazing

64-1, Preparing new

window for glazing

.

Preparing window flange for glazing

64-1, Preparing

window flange for glazing

.

Installation notes

64-1, Installation notes

.

Minimum curing time

64-1, Minimum curing time

.

Side window (Golf), assembly overview

Flush-bonded windows

13/2/2005

1. Side window

¡

Remove side window

64-1,

Undamaged side window, removing

¡

Installing side window

64-1, Side

window, installing

2. Ceramic coating

3. Sealing lip (component part of

pre-coating)

4. PUR adhesive sealant

¡

Bead cross section:

Width = 7 mm

Height = 11 mm (including pre-coating,
residual material on window glass and
window flange)

Flush-bonded windows

13/2/2005

¡

Minimum curing time

64-1,

Minimum curing time

5. Gap dimension - a - = 56 mm

¡

Gap dimension must be maintained
since distance is necessary for
securing roof base carrier

Undamaged side window, removing

- Remove side trim

.

Repair Manual, Body Interior, Repair Group 70, Pillar

and side trim

- Remove B-pillar trim

.

Repair Manual, Body Interior, Repair Group 70, Pillar

and side trim

- Removing side support for luggage compartment cover
and removing C-pillar trim

.

Repair Manual, Body Interior, Repair Group 70, Pillar

and side trim

- Insert plastic wedge between sealing lip and window
flange.

- Loosen sealing lip from window flange all around and
spray in Cleaning solution D 009 401 04 (as a substitute for
lubricant).

Flush-bonded windows

13/2/2005