Rear Window, Removing And Installing

Removing an Undamaged Window 

-- The rear lid trim panel is removed. Refer to LOWER REAR LID TRIM PANEL, REMOVING AND INSTALLING .

-- The roof spoiler is removed. Refer to OVERVIEW - SPOILER .

-- The rear window wiper is removed. Refer to Rear Window Wiper Motor -V12-, REMOVING AND INSTALLING

-- Disconnect rear window defroster and window antenna connectors and secure to center of window with adhesive tape.

-- 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.

Fig 1: Covering Awl Outlet Under Body Flange With Tape

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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 Around Under The Windshield

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-- Route cutting wire around rear window under the glass as shown in the illustration.

-- Mount both spools on the inside of the windshield as illustrated.

Fig 3: Mounting Spools Inside Of The 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 using the spool -1- and insert the plastic film -2- taken from the Cutting Tool for Bonded Windows VAS6452 to protect the wire and the window glass.

Fig 5: Tensioning Cutting Wire Using Spool

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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

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-- Move the spool and the guide awl as illustrated and cut free the section along the >>D-pillar<<.

Fig 8: Cutting D-Pillar Section

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

Fig 9: Cutting Windshield Up To Center

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-- Cut free the bottom of the windshield with the second spool.

Fig 10: Cutting Lower Section Of Windshield

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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 window free moving upward along the >>D-pillar<<.

Fig 12: Cutting Upward D-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 Top Of Windshield

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-- Remove the window with suction cups.

Damaged Rear Window, Removing 

-- Protect body and interior from glass splinters.

-- Remove glass pieces from adhesive material.

-- Disconnect rear window defroster and window antenna connectors.

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

-- Cut through the adhesive sealing material (with glass residue) in the from window opening using Window Cutter VAG1561A and Cutting Blade, Bent at Right Angle VAG1561/10

Preparations for the installing the rear window 

With New Window: 

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

-- Apply the Glass-/Paint Primer D 009 200 02 as described.

Applying Primer: 

Fig 14: Applying Primer To Window Molding

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-- Apply the glass/paint primer -3- to the adhesive surface on the glass -4- evenly in one stroke using the applicator -2-.

-- Beginning applying with saturated felt.

• 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.

-- Clean the repaired area with Cleaning Solution D 009 401 04 and then apply Glass/Paint Primer D 009 200 02.

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

-- Position the entire nozzle surface -2- on the 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 all around.

Fig 17: Applying Adhesive Sealing Material

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

-- Insert the rear window into window cut-out using suction cups.

-- 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.

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