Windshield

Windshield

Removing

Necessary tools and materials => [ Flush-Bonded Windows ] Description and Operation.

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

- Remove windshield wiper arms.

- Remove cowl panel trim.

- Remove left, middle and right sun visors.





- Remove rearview mirror.

- Remove trim from upper A-pillars and top of windshield.

- Pierce awl from Window Removing Kit (V.A.G 1755 ) or Cutting Tools For Glass (V.A.G 1351) through adhesive bead from inside to outside in lower left corner of windshield.

- Pull cutting cord through adhesive sealing material into inside of vehicle using awl.

- Lay cutting cord underneath and all around inside of windshield.





- Secure end of cutting cord at bolt - arrow - for securing window wiper frame.





- Slide Cover for Audi A4 Dash Panel (V.A.G 1474/13 ) between windshield and instrument panel.





- Secure beginning of cutting cord in winding device and cut out first area of adhesive (up to about center of windshield).

- Move spooling tool, as shown in illustration, and continue cutting.





- Move spooling tool, as shown in illustration, and attach relay pulley.





• Route cord as shown.

- Cut window free until cutting cord is no longer fed through idler pulley.

- Remove idler pulley and continue cutting window free.





- Move spooling tool, as shown in illustration, and attach relay pulley at upper part of window.





• Route cord as shown.

- Cut window free until cutting cord is no longer fed through idler pulley.

- Remove idler pulley and continue cutting window free.

- Repeat these steps in top left and bottom left corners of windshield.

- Completely cut window free.

- Cut through any adhesive beads that were not completely cut through using Electric Cutter (V.A.G 1561 A) and appropriate cutting blade.

- Remove window with two double suction cups.

Installing





- After preparatory work has been performed, apply the adhesive.

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

- - Arrow - indicates direction of application

• Cross-section thickness of adhesive bead - 1 - is determined by dimension of opening in nozzle tip and rate of application.

- Apply adhesive sealing material all around, as shown in illustration.





- Note varying spacing dimensions to window edge:





CAUTION!
Maintain specified distances of adhesive bead to window edges, otherwise there may be leaks.

- In the lower corners, adhesive bead must be applied in even curves at 12 mm distance to side window edge and 25 mm to lower window edge.

- On the lower window edge, the adhesive bead must increase from dimension - a - = 25 mm over dimension - f - = 30 mm to dimension - g - = 36 mm.

• Dimension - a - = 16 mm.

• Dimension - b - = 12 mm.

• Dimension - c - = 92 mm.

• Dimension - d - = 63 mm

• Dimension - e - = 25 mm

• Dimension - f - = 30 mm.

• Dimension - g - = 36 mm.

- Using two suction lifters, install windshield in windshield opening.

CAUTION!
Window must be installed within 15 minutes, otherwise bonding properties of adhesive will be impaired.

- Center window along sides.

- The window must not touch the cover trim retaining clips.

- Slide window up to upper spacer buffer stop.

"Caution- Safety information" sticker.





- Attach stickers on windshield (e.g. for airbag) in same position on new windshield.

• Determine dimensions - a - and - b - from removed window.