Windshield, Removing And Installing

-- Remove the windshield wiper arms. Refer to WINDSHIELD WIPER ARMS, REMOVING AND INSTALLING .

-- Remove the plenum chamber cover. Refer to PLENUM CHAMBER COVER, REMOVING AND INSTALLING .

-- Remove the left center and right sun visor. Refer to SUN VISOR, REMOVING AND INSTALLING .

-- Remove the interior rearview mirror. Refer to INTERIOR REARVIEW MIRROR, REMOVING AND INSTALLING .

-- Remove the left and right upper A-pillar trim panels. Refer to A-PILLAR TRIM PANEL, REMOVING AND INSTALLING .

-- 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: Identifying Poking Awl Through Adhesive Bead

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-- 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

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-- Mount both spools 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 spool -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 spool.

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

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-- If necessary, move the protective foil -3- along with the wire and cut the windshield free with the spool -1-.

-- Move the spool 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 spool 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 spool.

Fig 10: Cutting Windshield Lower Section

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-- Move the spool 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 spool over the center of the windshield as well as over the first spool 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.

With New Window:

-- Clean the adhesive surface on the window all around with Cleaning Solution D 009 401 04.

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

Applying Primer:

Fig 14: Applying Primer To Window Molding

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-- 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 Solution D 009 401 04and then apply the Glass And Paint Primer D 009 200 02.

Windshield, Installing

Dimensions for adhesive application:

Fig 15: Dimensions For Adhesive Application

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1. Adhesive Bead
2. Glass/Paint Primer
3. Washer

• Dimension -a- = 8 mm.
• Dimension -b- = 12 mm.
• Dimension -c- = note the different spacing dimensions to the window edge. Refer to -item  2- Adhesive Bead (See Figure).

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

Fig 16: Positioning Complete Surface Of Nozzle Onto Window

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

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

Fig 17: Applying Adhesive Sealing Material

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

-- Using suction cups, install the windshield.

-- Center window along sides.

• Distance from the window edge to the roof frame. Refer to -item  1- Windshield (See Figure).
• Secure the window to the top of the roof with adhesive tape.

-- Remove the molding from the frame before installing the plenum chamber cover. Refer to Figure.

-- Observe minimum curing time. Refer to MINIMUM CURING TIME FOR BONDED WINDOWS .