Volkswagen Golf / Golf GTI / Jetta. Manual - part 705

  

  

- Insert guide needle - 2 - under sealing lip - 3 - using 
handle - 1 - and knock through adhesive bead (use side 
area on lower edge of rear window). 

 

Hold guide needle as close to glass as possible.

- Remove handle and thread cutting cord through eye of 
needle. 

- Using pliers and wearing gloves, pull one end of cutting 
cord into vehicle interior. 

- Using small tube - 1 - , guide in cutting cord between lip 
and window flange. 

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

Flush-bonded windows

13/2/2005

  

  

- Place cutting cord around window as shown. 

Note: 

Press in cutting cord far enough to prevent damage to 
lip/spacer.  
 

- Pull through outer cord end inward and secure to Pulling 
grip V.A.G1351/1 to counterhold. 

- Apply cloth-reinforced adhesive tape to window flange on 
inside - 1 - . 

- Secure cord end to spooling tool. 

- 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. 

Damaged rear window, removing

 

- Protect body and interior from glass splinters. 

Flush-bonded windows

13/2/2005

  

- Remove glass pieces up to adhesive material. 

- Remove connectors for glass defroster and antenna.  

- Bond flange - 2 - all around with fabric reinforced 
adhesive tape. 

- Remove adhesive material (with glass residue) from 
window opening using electric cutter and  Knife 
V.A.G1561/10 (with stopper roll). 

Warning!  

 

Always wear protective goggles and leather gloves.

Rear window, 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

 . 

Rear window (Jetta), assembly overview

 

Flush-bonded windows

13/2/2005

 

1. Rear window 

¡

Removing rear window 

 

64-1, 

Undamaged rear window, removing

  

¡

Installing rear window 

 

64-1, Rear 

window, installing

  

 

2. Gap dimension - a - = 3 mm  

3. Sealing lip (component part of 

pre-coating)  

4. PUR adhesive sealant 

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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