Windshield, Removing And Installing: Removing

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-- 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 OVERVIEW - SUN VISORS .

-- Remove the interior rearview mirror. Refer to INTERIOR REARVIEW MIRROR .

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

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 shown in illustration.

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 shown in illustration.

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 shown in illustration.

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 shown in illustration) 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 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 shown in illustration) 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.

Fig 9: Cutting Windshield To Center

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

-- 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 shown in illustration.

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 shown in illustration) 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 VAG1561A 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 Solution D 009 401 04.

-- Apply Glass and Paint Primer D 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

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