Audi Workshop Service and Repair Manuals

Removing and installing windscreen –  Remove wiper arms → Rep. gr.92. –  Remove plenum chamber cover → Chapter. –  Remove sun visors (left-side, centre and right-side) → Rep. gr.70. –  Remove interior mirror → Rep. gr.68. –  Remove A-pillar trim panels (top left and right) → Rep. gr.70.   WARNING Always wear safety goggles and leather gloves when removing windscreen. –  Use wire reel -VAS 6452/1- to reel off about 6.50 metres of cutting wire (corresponding to 6 turns) and cut off. –  Mask over outlet of awl at bottom of body flange with adhesive tape -1- to avoid damage.

–  Pierce adhesive bead in this area with awl from inside to outside, as shown. –  Thread both ends of cutting wire -3- into awl -2- and pull through to the inside.

–  Position cutting wire under glass all around windscreen, as shown.   Caution The wire ends must not be twisted at the point where they pass through the adhesive bead -arrow-.

–  Attach both reels to inside of windscreen, as shown.

–  Insert end of cutting wire -1- into reel -2-.

–  Tension cutting wire and insert protective film -2- between dash panel and wire.

–  Cut clear the first area. While doing so, wire is guided into integrated idler pulley -arrow- on reel.

–  Additionally insert guide awl -2- into adhesive bead, as shown, and attach it to windscreen using suction pad so that wire runs along windscreen as close to the glass as possible. –  Adjust protective film -3- as necessary with length of wire and continue cutting clear using reel -1-.

–  Adjust reel and guide awl as shown, and cut clear area at A-pillar. –  Adjust reel and guide awl to approx. centre of windscreen, as shown.

–  Cut clear windscreen approx. to centre.

–  Use second reel to cut clear bottom area of windscreen.

–  Move reel up and insert guide awl, as shown.

–  Cut clear windscreen upwards along A-pillar.

–  Adjust reel over centre of windscreen and adjust first reel as shown and cut windscreen fully clear at top. –  Lift windscreen out of vehicle using two suction lifters. Preparations before installing windscreen –  Just before re-installing an undamaged windscreen, use electric cutter -V.A.G 1561 A- and scraper (25 mm) -V.A.G 1561/8- to cut back the remaining adhesive sealant on the windscreen and flange for an even surface, but do not remove completely.   Note The remaining sealant is required as a base for better adhesion of the new adhesive sealant.   Caution t  Keep bonding surface clean and free from grease. t  Do not cut back bonding surface until shortly before installation. t  Do NOT apply primer to bonding surface and do NOT use cleaning solution. If installing a new windscreen: –  Clean all around bonding surface with cleaning solution -D 009 401 04-. –  Apply glass/paint primer -D 009 200 02- as described in the following.   Caution The ceramic coating on the glass is not a primer. The glass must always be primed before applying adhesive sealant.

Applying primer: –  Use applicator -2- to apply glass/paint primer -3- evenly and in one movement onto windscreen -4- beside moulding -1-. –  Start application with fully soaked felt. l  Primer width approx. 20 mm l  Apply glass/paint primer centrally in relation to adhesive bead. l  Flash-off time: 10 minutes Windscreen flange: –  If windscreen flange has been damaged, paintwork structure must be repaired and, if necessary, anti-corrosion measures must be taken → Audi Paintwork Guide. –  Clean repaired area using cleaning solution -D 009 401 04- and then apply glass/paint primer -D 009 200 02-. Installing windscreen   Note The cross-section of the adhesive bead is determined by the nozzle opening and the rate of application.

Dimensions for applying adhesive: 1 -  Adhesive bead 2 -  Glass/paint primer 3 -  Windscreen l  Dimension -a- = 8 mm l  Dimension -b- = 12 mm l  Dimension -c-: note different distances from edge of windscreen → Item.

–  Apply full surface of nozzle -2- to windscreen. l  Direction of application -arrow- for adhesive bead -1-.

–  Apply adhesive sealant -1- all round windscreen -2-, as shown. –  When reinstalling an undamaged windscreen, apply adhesive to remaining adhesive bead. –  Install windscreen glass in windscreen opening using two suction lifters.   Caution Windscreen must be fitted within 15 minutes, otherwise the adhesive properties of the adhesive sealant will be impaired. –  Align windscreen glass so that spacing is equal on both sides. l  Distance from edge of windscreen to roof frame → Item. l  Secure windscreen to roof at top with adhesive tape. –  Pull protective strip -2- out of windscreen surround before fitting plenum chamber cover. –  Note minimum drying time → Anchor.