Glass, Window Regulators: Other Audi A3 8P facelift

SERVICING WINDOWS USING VAS 6092

Note. Windshields damaged by flying rocks can be repaired using the VAS 6092. These damaged areas must not exceed a certain dimension or lie within the driver's field of sight. For further details on use, refer to User's Manual enclosed with each kit.

MATERIALS

MINIMUM CURING TIMES

Cleaning when soiled by adhesive sealing material

It is recommended to use adhesive remover D 002 000 10 as a cleaning solution. Follow the safety precautions when using it.

Paint Surfaces

Clean the painted surface with a dry cloth. Clean off any dirt with adhesive remover D 002 000 10.

Plastic Trim

Allow the adhesive sealant to harden (approximately 1 hour) and then peel it off.

Scheme 41

1. Windshield Removal, refer to «WINDSHIELD»(ref-496128-S27428473342012082100000)
2. Window Adhesive Note varying spacing dimensions to window edge Observe curing times, refer to «MINIMUM CURING TIMES»(ref-496128-S18055740162012082100000).
3. Gap Cover Is cut through by cutting cord when removing window. Can be replaced separately (Scheme 42).
4. Plenum Chamber Cover Press into fastening strip only after window adhesive curing time has elapsed. Before installing, first remove protective piping on new window (Scheme 43).
5. Retaining Strip for Plenum Chamber Cover Is supplied with the windshield
6. Drip Rail Press into clamping strip only after window adhesive curing time has elapsed.
7. Retaining Strip Assembly, refer to «DRIP RAIL CLAMPING STRIP»(ref-496128-S08606506792012082100000)

Scheme 42

Replacing Gap Cover

Use a glass scraper to remove remainder of gap cover.

Clean adhesion surface using D 009 401 04.

Using a soft pencil, apply a marking in regular intervals of -a- = 10 mm -1mm on ceramic screen printed area.

Prime adhesion area up to this marking using D 009 200 02 and allow primer to air dry for at least 10 minutes.

Remove protective paper from double-sided adhesive tape -2-.

Install new gap cover onto window -1- in regular intervals -a- = 10mm -1mm (inner edge of primer marking) to window edge.

Press gap cover firmly onto window using an application roller.

Scheme 43

Removing Protective Piping

For a new window, protective piping -2- must be pull out of retaining strip -3- of windshield -1- before assembling plenum chamber cover -4-.

Reworking the window glass flange

If windshield flange has been repaired or replaced, paint structure should be restored and if necessary, corrosion repair measures should be taken.

Clean the surface with D 009 401 04 and then prime it with D 009 200 02.

After performing preparatory work, cut tip off nozzle as shown.

Scheme 44

Dimension -a- 12 mm.

8 mm wide adhesive bead.

Arrow- indicates direction of application

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

Apply adhesive sealing material along perimeter according to illustration.

Scheme 45

Distance from the center of the adhesive bead to the window edge: 8 mm

Using double suction cups, install the windshield.

Center window along sides.

Spacing between edge of windshield and roof frame must be 4 mm.

Press drip rail into clips -3- until it stops only after curing time has elapsed for adhesive -1-.

Scheme 46

When pressing in drip rail, make sure sealing lip lies flat against windshield and does not slip behind edge of windshield.

Hollow rivet -2

Secure window in window opening with adhesive tape.

Adhesive Sealant, Removing from Window

It is recommended to use adhesive remover D 002 000 10 as a cleaning solution. Follow the safety precautions when using it.

Paint Surfaces

Clean the painted surface with a dry cloth. Clean off any dirt with adhesive remover D 002 000 10.

Plastic Trim

Allow the adhesive sealant to harden (approximately 1 hour) and then peel it off.

Scheme 47

1. Rear Window Undamaged side window, removing, refer to «UNDAMAGED REAR WINDOW»(ref-496128-S41098615032012082100000). Removing damaged rear window, refer to «DAMAGED REAR WINDOW»(ref-496128-S11369667272012082100000). Align distance -a- to rear lid at top and bottom.
2. Adhesive Sealing Material Note varying spacing dimensions to window edge. Space to upper window edge -a- = 18.5 mm. Space to lower window edge, dimension = 21 mm Space to side window edge, dimension = 12 mm Dimension for primer application and adhesive bead cross-section see scheme 11
3. Spacer
4. Spacer

WINDSHIELD

Removing

Remove the windshield wiper arms.

Remove cowl panel trim.

Remove the left and right drip rails from the clamping strips starting from the top.

Remove sun visors on left, center and right. Refer to Removal and Installation

Remove the interior rearview mirror. Refer to Removal and Installation

Remove the A-pillar upper trim. Refer to Removal and Installation .

Use awl to pierce through adhesive sealing material on lower left of window from inside to outside.

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

Scheme 48

Lay cutting cord underneath and all around inside of windshield.

Scheme 49

In top area, insert cutting cord -2- between window -1- and gap cover -3-.

Scheme 50

Gap cover is cut through during the cutting procedure.

Note. If a removed window must be reinstalled, a new gap cover can be glued onto window edge.

Secure end of cutting cord to windshield wiper arm securing screw.

Scheme 51

Insert protective foil V.A.G 1474/13 between windshield and instrument panel.

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

Move spooling tool as shown, and continue to cut out adhesive sealing material.

Scheme 52

Move spooling tool as shown and attach relay pulley.

Scheme 53

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.

Scheme 54

Replace spool as shown and position idler puller in upper part of window.

Scheme 55

Route cord as shown.

Insert protective foil V.A.G 1474/11 between windshield and headliner.

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

Remove idler pulley and continue cutting window free.

Repeat procedure in upper and lower left parts of windshield.

Cut glass completely free in this manner.

Remove windshield from windshield opening using suction lifter.

Installing

Scheme 56

1. Windshield Applying primer. see scheme 4Applying adhesive. see scheme 5
2. Gap Cover Is supplied with the windshield Can be replaced separately
3. Window Adhesive Dimensions for adhesive bead see scheme 5 Dimension -a- 8 mm± 2 along perimeter on window edge Observe curing times, refer to «MINIMUM CURING TIMES»(ref-496128-S25487209832012082100000)
4. Drip Rail Press into clamping strip only after window adhesive curing time has elapsed.
5. Retaining Strip for Plenum Chamber Cover Is supplied with the windshield No replacement part.
6. Protective Piping
7. Plenum Chamber Cover Press into fastening strip only after window adhesive curing time has elapsed. Before assembly, pull out protective piping -6- first on a new window.

Scheme 57

1. Drip Rail Pry out of clamping strip, starting from below. When assembling, press into clamping strip starting from above, and continuing downward.
2. Retaining Strip The windshield is removed. To remove, drill off rivet head of hollow rivet -3- and knock rivet shaft through.
3. Hollow Rivet

UNDAMAGED REAR WINDOW

Remove rear lid trim.

Remove rear windshield wiper.

Open rear lid and guide needle using handle -1- under sealing lip and pierce adhesive bead.

Scheme 58

Remove handle and thread cutting cord through eye of needle.

Using pliers and wearing gloves, pull one end of cutting cord into vehicle interior.

Using plastic wedge, loosen sealing lip from glass flange and spray with D 009 401 04 cleaning solution (lubricant replacement).

Route the cutting wire around the window glass.

Scheme 59

Using needle and handle, pull second cutting cord end -B- inward as shown.

Scheme 60

Thread cutting cord end -A- into spooling tool V.A.G 1654 and secure.

Fasten cutting cord end -B- to lid hinge.

Scheme 61

Fasten V.A.G 1654 spooling tool as shown to rear window.

Scheme 62

When cutting side area, press cutting cord in direction of arrow.

Cut bottom of window free.

Move spooling tool and cut window free.

Scheme 63

When cutting lower window area, press cutting cord in direction of arrow.

Cut window free in side area.

Move spooling tool and cut window free.

When cutting side area, press cutting cord in direction of -arrow-.

Scheme 64

Cut top of window free.

Move spooling tool and cut window free.

When cutting upper area, press cutting cord in direction of -arrow-.

Scheme 65

Cut window completely free and remove from tailgate using double suction tool V.A.G 1344.

DAMAGED REAR WINDOW

Protect body and interior from glass splinters.

Remove glass pieces from adhesive material.

Disconnect window heater connections.

Bond flange all around with fabric reinforced adhesive tape.

Remove adhesive sealing material (with glass residue) from window opening using electric cutter and knife V.A.G 1561/10 (with stopper roll).

BROKEN SIDE WINDOW

Protect body and interior from glass splinters.

Remove glass pieces from adhesive material.

Bond flange all around with fabric reinforced adhesive tape.

Remove adhesive sealing material (with glass residue) from window opening using electric cutter and knife V.A.G 1561/10 (with stopper roll).

SIDE WINDOW

Removing

Remove the following trim pieces

B-pillar trim. Refer to Removal and Installation

C- and D-pillar trim. Refer to Removal and Installation

Loosen the side luggage compartment trim panel, but do not remove it. Refer to Removal and Installation .

Pull off door seal from door flange in area of trim panel.

Pierce through adhesive sealing material using a guide needle with handle from V.A.G 1755 window removing kit.

Remove handle and thread cutting cord through eye of the guide needle.

Scheme 66

Pull cutting cord end -A- inward (use pliers and protective gloves) to opposite window side with guide needle from V.A.G 1755 window removing kit.

Scheme 67

Pull cutting cord -B- with small tube from V.A.G 1755 under molding of side window.

Scheme 68

Insert cutting cord completely around window.

Scheme 69

Pierce through adhesive sealing material using a guide needle with handle from V.A.G 1755 window removing kit.

Remove handle and thread end of cutting cord -B- through eye of the guide needle.

Pull through cutting cord end -B- with guide needle inward (use pliers and protective gloves).

Secure cutting cord end -B- for example, to belt guide console.

Attach V.A.G 1654 as shown and secure cutting cord inside it.

Scheme 70

Cut first area at B-pillar and window bottom.

Scheme 71

Note. Press cutting cord in direction of chassis during cutting procedure.

Position V.A.G 1474/1 as depicted in the illustration.

Scheme 72

Move V.A.G 1654 and continue cutting.

Position V.A.G 1474/1 as depicted in the illustration.

Scheme 73

Move V.A.G 1654 and continue cutting.

Remove side window using V.A.G 1344.

Scheme 74

Press side window into window opening using V.A.G 1344 and align it according to window opening.

Scheme 75

Rivet side window at top and bottom to B-pillar.

Secure window in opening using adhesive tape.

Observe curing time.

Slide trim panel -1- with clips onto side window -4-.

Scheme 76

Rivet trim panel with hollow rivets -2-.

Reapply door seal -3- on body flange.

Scheme 77

Special tools and workshop equipment required

1. Cutting tool kit V.A.G 1474 B
2. Suction lifter V.A.G 1344
3. Cutting tools for glass V.A.G 1351
4. Window removing kit V.A.G 1755
5. Cartridge gun V.A.G 1628
6. Cartridge heater V.A.G 1939A
7. Electric cutter V.A.G 1561 A

Scheme 78

Special tools and workshop equipment required

Scheme 79

1. Blade, offset V.A.G 1561/2
2. Blade, offset V.A.G 1561/3
3. Scraper V.A.G 1561/8
4. Blade, offset V.A.G 1561/10
5. Double cartridge gun VAS 5237
6. Spooling tool V.A.G 1654 A