Convertible Top - Eliminating Leaks
84VW1Applies To RABBIT CONVERTIBLE
Group
61
Subject:
Convertible Top
Part Identifier 6139-6145
Key Points
Eliminating leaks
C
Number
84-01
March 27, 1984
Modified seals are available to eliminate leaks at the windshield frame, header and door, door window and roof frame.
These seals are installed in production vehicles beginning with Model Year 1984.
When leaks occur on Model Year 1980-83 vehicles, all the modified seals must be installed as a set. They cannot be installed individually.
^ seal for top header - Part No. 155 871 349 C
^ door seal - Part No. 155 837 911 D/912 D
^ seal for roof frame - Part No. 155 871 357 D/358 D
^ insert bar - Part No. 155 871 355 C/356 C
^ seal - Part No. 155 871 431 A
Tools and material required:
^ rivet gun
^ die grinder
^ weatherstrip adhesive Part No. D 001 300
^ silicone sealant Part No.. AMV 176 000 05
Top header seal, replacing
Work sequence
- drill rivets out (arrow) and remove seal
- remove adhesive remaining on header
- align new seal, Part No. 155 871 349 C, on frame and press onto flange
- install rivets, Part No. N 901 068.01
- stick seal on in shaded area with D 001 300 adhesive
- seal area A, approx. 200 mm (8 in.) wide, with silicone sealant, Part No. AMV 176 000 05
Door seals, replacing
Work sequence
- remove door seals (see Repair Manual, Group 57)
- remove adhesive remaining on door
- mark dimension b, 65 mm (2 9/16 in.) on door window frame (use template on page 4)
- cut off marked area
- remove burrs from cut edge, prime and paint
- check tightness of screws for window guide channels
- install new door seal Part No. 155 837 911 D/912 D
- join outer and inner ends of seal (arrows) to door with adhesive, Part No. D 001 300
Roof frame seals and insert bars, replacing
Work sequence
- remove roof frame seals and insert bars
- install plastic clip (arrow)
- cut seal, Part No. 155 871 431 A, to length and stick on underside of insert bars Insert bar Part No. 155 871 355 C/356 C
- apply a thin bead of sealant to roof frame (arrows). Sealant Part No. AMV 176 000 05
- fasten insert bars to roof frame. Close top to align.
- install roof frame seal into insert bar on roof frame. Use a wooden wedge or similar tool. Roof frame seal Part No. 155 871 357 D/358 D.
- close top and align roof frame seal so that forward end is flush and parallel with header seal (arrow)
- drill a 3 mm hole through roof frame seal into roof frame (arrow)
- pull seal off roof frame for a length of approx. 55 mm (2-1/4 in.) and seal contact surface in frame with sealant, Part No. AMV 176 000 05
- reinstall seal
- secure roof frame seal with screw
Labor operation - 61 45 21 0
T.U. - 160
(replacement of entire seal set)
Template for door window frame