Rear Window
Rear Window
Insert a plastic washer at the outlet point of the cutting wire as protection against paint damage, for example.
- Gradually push a cutting wire through the adhesive bead from the inside to the outside with needle-nose pliers as shown.
- Route cutting wire around rear window under the glass as shown in the illustration.
- Loosen the hex bolt - arrow - on the rear lid hinge - 1 - and clamp the end of cutting wire- 2 - securely with it.
- Clamp the cutting wire in the spool.
- After removing window, tighten bolt to 21 Nm.
- Cut first area free.
- Move spooling tool as shown and position idler pulley on lower part of window.
• Wire run according to figure.
- Cut window free until the cutting wire is no longer fed through the idler pulley.
- Remove idler pulley and continue cutting window free.
- Replace spool as shown and position idler puller in upper part of window.
• Wire run according to figure.
- Cut window free until the cutting wire is no longer fed through the idler pulley.
- Remove idler pulley and continue cutting window free.
- Repeat procedure in upper and lower right part of window.
- Cut glass completely free in this manner.
- Remove window with double suction cups.
Damaged Rear Window, Removing
When removing a window, always wear protective eyewear and leather gloves.
- 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.
- Remove adhesive material (with glass residue) from window opening using (V.A.G 1561A) and (V.A.G 1561/10) (with stopper roll).
Preparations for Installing Rear Window
• When reusing the undamaged window, cut rest of adhesive material on window and flange with (V.A.G 1561 A) and (V.A.G 1561/8) so it is even, but do not remove completely.
• Residual material acts as a base for the new adhesive sealing material.
• Keep adhesive surface free of dirt and grease.
• Only cut back adhesive surface shortly before installation.
• Do not prime or use a cleaning solution on the adhesive surface.
With New Window:
- Clean window in adhesive area between inner - 1 - and outer adhesive stopper profiles - 2 - using Cleaning Solution (D 009 401 04).
- Apply Glass and Paint Primer (D 009 200 02) as described below.
• Ceramic application on window is not primer! It must be primed before the application of adhesive sealing material!
Applying Primer:
Primer conducts electricity and must not touch rear window defroster distributing wire.
- Apply primer - 3 - with applicator - 2 - evenly in one stroke between adhesive stopper profiles on window - 4 -.
- Beginning applying with saturated felt.
• Apply primer over entire width between stopper profiles.
• Drying time 10 minutes
• If the paint on the window flange is damaged when the rear window is removed, repair it according to the Audi paint handbook.
- First clean corrected area with Cleaning Solution (D 009 401 04) and then apply Glass and Paint Primer (D 009 200 02).
Rear Window, Installing
1 Rear window
• Insert in window opening with double suction cups.
2 Inner adhesive stopper profile
• Prevents adhesive from touching distributing wire.
3 Outer adhesive stopper profile
• Prevents adhesive from leaking to outside.
Installation
• Cross-section thickness of adhesive bead is determined by dimension of opening in nozzle tip and rate of application.
Dimensions for adhesive application:
1. Adhesive sealing material
2. Primer
3. Window
• Dimension - A - = 8 mm +/- 2 mm
• Dimension - b - = 12 mm 2 mm
- Position complete surface of nozzle - 2 - onto window.
• Application direction - arrow - for adhesive bead - 1 -.
- Apply adhesive sealing material all around between adhesive stopper profiles.
- With an undamaged removed window, apply adhesive to remaining bead.
- Insert the rear window into window cut-out using double suction cups.
The window must be installed within 15 minutes or the adhesive sealing material will not adhere properly.
- Center window along sides.
- Note distance to upper lid edge = 2 mm.
- Observe minimum curing time => [ Minimum Curing Times ] Flush-Bonded Windows.