Windshield, Removing And Installing

-- Remove the windshield wiper arms. Refer to WINDSHIELD WIPER ARMS .

-- Remove the plenum chamber cover.

-- Remove left, center and right sun visors. Refer to Removal and Installation .

-- Remove the interior rearview mirror. Refer to Removal and Installation .

-- Remove upper A-pillar trim on left and right. Refer to Removal and Installation .

WARNING:

When removing a window, always wear protective eyewear and leather gloves.

-- Unroll with the Cutting Tool for Bonded Windows - Wire Reel VAS6452/1 approximately 6.5 meters of cutting wire (approximately six turns) and cut it.

-- Cover the awl outlet under the body flange with tape -1- to prevent damaging it.

-- Poke the awl through the bead of adhesive from the inside to the outside as illustrated.

Fig 1: Poking Awl Through Adhesive Bead

Courtesy of AUDI OF AMERICA, LLC

-- Feed both cutting wire ends -3- into the awl -2- and pull it in.

-- Place the cutting wire all the way around under the windshield as illustrated.

Fig 2: Placing Cutting Wire All Around Under The Windshield

Courtesy of AUDI OF AMERICA, LLC

CAUTION:

The ends of the wire must not be twisted when cutting through the adhesive -arrow-.

-- Mount both reel devices on the inside of the windshield as illustrated.

Fig 3: Mounting Spools On Inside Of Windshield

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-- Insert the ends of the cutting wire -1- into the reel device -2-

Fig 4: Inserting Ends Of Cutting Wire Into Spool

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-- Tension the cutting wire and place the protective foil -2- between the instrument panel and the wire

Fig 5: Tensioning Cutting Wire And Placing Protective Foil Between Instrument Panel And Wire

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-- Cut the first section open, while doing this, the wire is guided into the integrated roller -arrow- on the reel device.

Fig 6: Cutting First Section Open

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-- Insert an additional guide awl -2- into the adhesive and secure it to the windshield with the suction cup as illustrated to make sure that the wire runs as close to the windshield as possible.

Fig 7: Inserting Additional Guide Awl Into Adhesive And Securing Suction Cup To Windshield

Courtesy of AUDI OF AMERICA, LLC

-- If necessary, move the protective film -3- along with the wire and cut the windshield free with the reel device -1-.

-- Move the reel device and the guide awl as illustrated and cut free the section along the >>A-pillar<<.

Fig 8: Cutting A-Pillar Section

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-- Moved the reel device and guide awl approximately to the center of the windshield.

-- Cut free the windshield up to about the center.

Fig 9: Cutting Windshield To Center

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-- Cut free the bottom of the windshield with the second reel device.

Fig 10: Cutting Windshield Lower Section

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-- Move the reel device upward and insert the guide awl as illustrated.

Fig 11: Moving Spool Upward And Inserting Guide Awl

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-- Cut the windshield free moving upward along the >>A-pillar<<.

Fig 12: Cutting Upward Along A-Pillar Windshield

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-- Move the reel device over the center of the windshield and over the first reel device as illustrated and cut free the rest of the windshield along the top.

Fig 13: Cutting Along Top Of Windshield

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-- Remove the windshield from the vehicle with the suction cups.

Preparations for Installing the Windshield

-- When reusing the undamaged window, cut the rest of the adhesive material on the window and flange with the Window Cutter VAG1561 A and Window Cutter - Scraper (2 pc.) VAG1561/8 so it is even, but do not remove it completely.

NOTE:

The remaining material acts as a base for the new adhesive to be applied.

CAUTION:

Keep the adhesive surface free of dirt and grease.
Cut back the adhesive surface shortly before installing.
Do not prime or use a cleaning solution on the adhesive surface.

With New Window:

-- Clean around the adhesion surface using Cleaning SolutionD 009 401 04.

-- Apply Glass and Paint PrimerD 009 200 02 as described below.

CAUTION:

Ceramic application on window is not primer! It must be primed before the application of adhesive sealing material!

Applying Primer:

Fig 14: Applying Primer To Window Molding

Courtesy of AUDI OF AMERICA, LLC

-- Apply glass-/paint primer -3- with applicator -2- evenly in one stroke near the window molding -1- on the window -4-.

-- Beginning applying with saturated felt.

Primer width approximately 20 mm.
The glass/paint primer must be positioned in the center of the adhesive bead.
Curing time 10 minutes

Window Flange:

-- If the window glass flange was damaged, the paint must be repaired and corrosion protection must be applied, if necessary. Refer to the Audi Paint Guide.

-- First clean the repaired area with Cleaning SolutionD 009 401 04 and then apply the Glass And Paint PrimerD 009 200 02.

Windshield, Installing

NOTE:

Cross-section thickness of adhesive bead is determined by dimension of opening in nozzle tip and rate of application.

Dimensions for adhesive application:

Fig 15: Dimensions For Adhesive Application

Courtesy of AUDI OF AMERICA, LLC

Adhesive Bead
Glass/Paint Primer
Window

Dimension -a- = 8 mm
Dimension -b- = 12 mm
Dimension -c- = note the different spacing dimensions to the window edge. Refer to -item 2- in OVERVIEW - WINDSHIELD .

-- Position complete surface of nozzle -2- onto window.

Fig 16: Positioning Complete Surface Of Nozzle Onto Window

Courtesy of AUDI OF AMERICA, LLC

Application direction -arrow- for adhesive bead -1-.

-- Apply adhesive sealing material -1- all around on window -2- according to illustration.

Fig 17: Identifying Special Tool VAS 5237

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-- With an undamaged removed window, apply adhesive to remaining bead.

-- Using suction cups, install the windshield.

CAUTION:

The window must be installed within 15 minutes or the adhesive sealing material will not adhere properly.

-- Center window along sides.

Distance from the window edge to the roof frame. Refer to -item 1- in OVERVIEW - WINDSHIELD .
Secure the window to the top of the roof with adhesive tape.

-- Before installing plenum chamber cover, first remove protective profile -2- from the frame.

-- Observe the minimum curing time. Refer to MINIMUM CURING TIMES .