Glass, Window Regulators (sedan) Audi A4 B8

MATERIALS

1. Double cartridge pistol VAS 5237 must be used to process this material.

1. Heat according to manufacturer's instructions using cartridge heater V.A.G 1939 A.

SERVICING WINDOWS USING WINDOW REPAIR Kit AND TALON REPAIR RESIN

Special tools and workshop equipment required

1. Window Repair Kit VAS 1993 or VAS 6092

Note. Windshields with stone chips can be repaired with window repair Kit VAS 6092 and repair resin, Talon VAS 1993/2. 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.

MINIMUM CURING TIMES

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. Remove any remaining dirt with adhesive remover D 002 000 10.

Plastic Trim

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

WINDOWS, RESEALING

Allow leaky area to dry, and clean it.

Apply adhesive sealing material to leaking area between window and sheet metal flange and spread.

Allow the adhesive to harden.

Perform water test.

Perform visual inspection of vehicle interior.

WINDSHIELD OVERVIEW

Note. On vehicles equipped with lane assist, the camera must be recalibrated if the windshield has been replaced. Refer to [For engine(s) CAEB, CALA, CCBA] Removal and Installation .

Scheme 1

1. Windshield Distance to roof dimension -a- = 2 mm. Align the side distance -c-.
2. Adhesive Sealing Material Observe minimum curing time. Refer to «MINIMUM CURING TIMES»(/audi/a4/b8-2007-2012/remont/windows/#glass-window-regulators-sedan__minimum-curing-times) . Dimension -b- = 17 mm ±2 mm Dimension -d- = 8 mm ±2 mm Dimension -e- = 12 mm ±2 mm
3. Gap Cover No replacement part When removing the window, the cutting wire must be pulled under the gap cover.
4. Drip Rail
5. Plenum Chamber Cover Molding No replacement part With a new window, protective piping must first be removed before installing plenum chamber cover.
6. Plenum Chamber Cover Press into retaining strip only after window adhesive curing time is complete (3 hours).

Water Deflector, Removing

Scheme 2

1. Pop Rivet quantity: 5 Rivet the guide rails beginning at the top.
2. Guide Rail To remove, drill out rivet heads -4- and drive out rivet shafts.
3. Drip Rail Press into the guide rail as far as the stop, beginning at the top and working toward the bottom. Check for flushness at the transition to the A-pillar.

Scheme 3

With a new windshield -1-, protective piping -2- must be removed from molding -3- before installing plenum chamber cover -4-.

Scheme 4

1. Side Window Roof trim molding and side trim molding removed, refer to «ROOF TRIM STRIP OVERVIEW»(/audi/a4/b8-2007-2012/remont/mirrors/#exterior-equipment-sedan__roof-trim-strip-overview) . When installing a new window, first install securing pins on the C-pillar and D-pillar and then press the window into the cut-out. If a side window is going to be installed, then secure it to the C-pillar and D-pillar with adhesive tape.
2. Adhesive Sealing Material -- Observe minimum curing time, refer to «FLUSH-BONDED WINDOWS => Minimum curing time (--> curing time)»(/audi/a4/b8-2007-2012/remont/windows/#glass-window-regulators-sedan) .
3. Roof Trim Molding The roof trim molding is clipped onto the body.
4. Securing Pin No replacement part Is cut through when removing window.
5. Decorative Trim Strip Only vehicle with gloss package.
6. Molding No replacement part. Must not be damaged in field of vision.

Scheme 5

1. Rear Window Distance -a- to roof = 2 mm. Center the distance -d- to the D-pillar = 3 mm. Before removing, disconnect all electrical connectors and secure the terminals to the middle of the window on the inside using adhesive tape.
2. Adhesive Sealing Material Bead width = 8 mm ± 2 mm Bead height = 12 mm +2 mm Distances to the window edge: Dimension -b- = 16.5 mm Dimension -c- = 21.5 mm. Dimension -e- = 16.5 mm.
3. Spacer Make 3 markings each on the top and bottom edges of the window.
4. Adhesive Stop Profile Distance to the edge of the window -dimension f- = 24 mm Bond the adhesive stop profile directly by the window defroster distributing wire. Window adhesive must not come into contact with the rear window defroster distributing wire.

FRONT DOOR WINDOW OVERVIEW

Note. Window regulator must be installed before installing window.

Scheme 6

1. Door Window Removal, refer to «FRONT DOOR WINDOW»(/audi/a4/b8-2007-2012/remont/windows/#glass-window-regulators-sedan) .
2. Window Regulator Remains installed when removing the door window.
3. Door
4. Nuts 6 Nm
5. Speaker Removed, refer to «[For engine(s) CAEB, CALA, CCBA] Removal and Installation»(/audi/a4/b8-2007-2012/remont/gauges-instrument-panels/#instruments-sedan) .
6. Bolt 1.5 Nm
7. Bolt 6 Nm
8. Cover Unclip

Scheme 7

1. Door Window To remove, lower the door window into the door until the screws in the inner door panel are visible through the holes -arrow-. Push the bolt clamping pins. Push the bolts through, tilt the window inside the door and remove it. NOTE: Remove the clamping pins and bolts from the door
2. Window Regulator The window regulator remains installed inside the door.
3. Door
4. Nut 6 Nm
5. Cover Installed
6. Bolts Two-part with clamping pin. The bolts can be re-used.

FLUSH-BONDED WINDOWS

Special tools and workshop equipment required

1. Cutting Tool Kit Vas 6452
2. Wire Spool Vas 6452/1
3. Cutting Tool Kit Wire Vas 6452/2
4. Cutting Tools For Glass V.A.G 1351
5. Pull Handle V.A.G 1351/1
6. Suction Lifter V.A.G 1344
7. Electric Cutter V.A.G 1561A
8. Angled Blade V.A.G 1561/10
9. Universal Cutting Blade V.A.G 1561/11
10. Scraper (15+25 Mm) V.A.G 1561/7+8
11. Double Cartridge Gun Vas 5237
12. Cartridge Gun V.A.G 1628
13. Cartridge Heater V.A.G 1939A

Minimum curing time

Adhesive Sealant, Removing from Window

Using adhesive remover D 002 000 10 is recommended. Always follow the safety precautions when using adhesive remover.

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 8

Note. When removing the Rain/Light Recognition Sensor -G397-, a foil will be loosen; replace the foil before re-installing.

Remove the exterior mirror. Refer to Removal and Installation

1. Retaining plate -1
2. Rain/light recognition sensor -G397- -2
3. Retaining clip -3

Scheme 9

Disconnect electrical connector.

Press clip -2- outward at -arrows-, for example, with a small screwdriver.

Remove clips -2- from mirror base -1-.

Remove the rain/light recognition sensor -G397- -3- from the mirror base.

A sensor foil remains affixed to the windshield.

If the same windshield is being re-installed, remove the sensor foil from the glass including any remaining adhesive.

Clean the surface with cleaning solution D 009 401 04.

Install the rain/light recognition sensor -G397

If necessary, also remove the sensor foil from the rain/light recognition foil -G397-.

Carefully pull the sensor foil -2- from the rain/light recognition sensor -G397- -1-.

Scheme 10

Clean the surface with cleaning solution D 009 401 04.

Peel silicon paper -3- from sensor foil -2-.

Scheme 11

The transparent protective film -1- remains on the sensor foil as an assembly aid.

Place the sensor foil -1- on the rain/light recognition sensor -G397- -2- using a transparent protective foil.

Scheme 12

Push the sensor foil through the protective foil -1- so that there are no air bubbles onto the rain/light recognition sensor -G397- -2- as illustrated.

Scheme 13

Now remove transparent protective foil -1- from sensor foil -2-.

Scheme 14

Spray the sensor foil -1- completely with cleaning solution D 009 401 04 and install the rain/light recognition sensor -G397- into the mirror base.

Scheme 15

Press sensor clips on mirror base.

Replace the rain/light recognition sensor -G397

Note. To remove sensor, proceed as described above.

If necessary, completely remove any foil from the old rain/light recognition sensor -G397- from the windshield.

Clean the contact surface on the windshield using cleaning solution D 009 401 04.

Scheme 16

Press the surface -arrows- on the cap -1- lightly together and pull it off the rain/light recognition sensor -G397- -2-.

Spray the sensor foil -1- completely with cleaning solution D 009 401 04 and install the rain/light recognition sensor -G397- into the mirror base.

Mount the rain/light recognition sensor -G397- on the windshield free of bubbles and press the clamp onto the mirror base.

WINDSHIELD

Remove windshield wiper arms. Refer to [For engine(s) CAEB, CALA, CCBA] Removal and Installation .

Remove the plenum chamber cover. Refer to PLENUM CHAMBER COVER .

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

Remove the interior rearview mirror. Refer to Removal and Installation .

Remove upper A-pillar trim on left and right. Refer to Removal and Installation .

From the wire spool VAS 6452/1, pull out approximately 6.5 meter of cutting wire (about 6 turns) and cut it.

Cover the awl outlet under the body flange with tape -1- to prevent damaging it.

Poke the awl through the bead of adhesive from the inside to the outside as illustrated.

Scheme 17

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.

Scheme 18

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

Scheme 19

Insert the ends of the cutting wire -1- into the spool -2

Scheme 20

Tension the cutting wire and place the protective foil -2- between the instrument panel and the wire

Scheme 21

Cut the first section open, while doing this, the wire is guided into the integrated roller -arrow- on the spool.

Scheme 22

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.

Scheme 23

If necessary, move the protective foil -3- along with the wire and cut the windshield free with the spool -1-.

Move the spool and the guide awl as illustrated and cut free the section along the A-pillar.

Scheme 24

Moved the spool and guide awl approximately to the center of the windshield.

Scheme 25

Cut free the windshield up to about the center.

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

Scheme 26

Move the spool upward and insert the guide awl as illustrated.

Scheme 27

Cut free the windshield along the A-pillar upward.

Scheme 28

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.

Scheme 29

Remove the windshield from the vehicle with the suction cups.

Preparations for installing the windshield

When reusing the undamaged windshield, cut rest of adhesive material on windshield and flange with Electric Cutter V.A.G 1561 A and Scraper (25 mm) V.A.G 1561/8 so it is even, but do not remove completely.

Note. Residual material acts as a base for the new adhesive sealing material.

With new window

Clean the adhesive surface all the way around with cleaning solution D 009 401 04.

Apply Glass and Paint primer D 009 200 02 as described below.

Applying primer

Scheme 30

Apply glass-/paint primer -3- with applicator -2- evenly in one stroke near the window molding -1- on the window -4-.

Beginning applying with saturated felt.

1. primer width approximately 20 mm.
2. The glass-/paint primer must be positioned in the center of the adhesive bead.
3. Curing time 10 minutes

Window flange

If the windshield flange was damaged, then it must be repainted.

First clean corrected area with Cleaning solution D 009 401 04 and then apply Glass and Paint primer D 009 200 02.

Windshield, Installing

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

Dimensions for adhesive application

Scheme 31

1. Adhesive sealing material
2. Glass/paint primer
3. Window

1. Dimension -a- = 8 mm
2. Dimension -B- = 12 mm
3. Dimension -c- = note varying spacing dimensions to window edge. Refer to item 2 .

Position complete surface of nozzle -2- onto window.

Scheme 32

1. Application direction -arrow- for adhesive bead -1-.

Apply adhesive sealing material -1- all around on window -2- according to illustration.

Scheme 33

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

Using suction cups, install the windshield.

Center window along sides.

1. Distance from the edge of the windshield to the roof frame. Refer to item 1 .
2. Secure the window to the top of the roof with adhesive tape.

Before installing plenum chamber cover, first remove protective profile -2- from the frame.

Observe minimum curing time. Refer to MINIMUM CURING TIMES .

SIDE WINDOW

Undamaged side window, removing

Vehicles with gloss roof trim molding

Roof trim molding and side trim molding removed. Refer to ROOF TRIM STRIP OVERVIEW .

Vehicles with standard roof trim molding

Unclip the roof trim molding.

Scheme 34

Route the cutting wire around the side window as shown in the illustration.

Secure X and Y ends in two pull grips from special tool Cutting Tools For Glass V.A.G 1351.

Pull cutting wire forward in direction of arrow -A- using light sawing motions and cut through lower adhesive sealing material at side panel and at roof frame.

In this way, first the securing pin on the rear of the window and then the adhesive bead are cut through.

Then pull cutting cord through in direction of -arrow B- downward through adhesive sealing material.

Remove window from window opening.

Broken Side Window, Removing

Protect body and interior from glass splinters.

Bond flange all around with fabric reinforced adhesive tape.

Remove glass pieces from adhesive material.

Remove adhesive material (with glass residue) from window opening using electric cutter V.A.G 1561A and knife V.A.G 1561/11 (with stopper roll).

Preparations for installing side window

When reusing an undamaged window, cut remaining adhesive sealing material on window and flange using a carpet knife so that it is even, but do not remove completely!

Note. Residual material acts as a base for the new adhesive sealing material.

With new window

Clean the adhesive surface all the way around with cleaning solution D 009 401 04.

Apply glass-/paint primer D 009 200 02 all around the adhesive surface.

1. Curing time 10 minutes.

Side Window, Installing

The roof trim molding and side trim molding must be installed before installing the side window.

Note. 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. Glass/paint primer
3. Window

1. Dimension -a- = 8 mm +2 mm
2. Dimension -b- = 12 mm +3 mm
3. Distance -c- = to window edge is given through the window molding.

Position complete surface of nozzle -2- onto window.

1. Application direction -arrow- for adhesive bead -1-.

Apply adhesive sealing material all around near window molding.

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

Note. Use 1K Window AdhesiveDH 009 100 03 (small cartridge), or 2K Window Adhesive Kit DA 004 600 A2 can also be used if more than one window must be bonded.

If the window is new, first insert the securing pin in the C-pillar, D-pillar and then press the window into the cut-out.

If a side window is going to be installed, then secure it to the C-pillar and D-pillar with adhesive tape.

Observe minimum curing time. Refer to FLUSH-BONDED WINDOWS => Minimum curing time (--> curing time) .

REAR WINDOW

Special tools and workshop equipment required

1. Cutting Tool Kit VAS 6452

Undamaged Rear Window, Removing

1. C-pillar trim removed.
2. The high-mounted brake lamp is removed.

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

From the wire spool VAS 6452/1, pull out approximately 6.5 meter of cutting wire (about 6 turns) and cut it.

Cover the awl outlet under the body flange with tape -1- to prevent damaging it.

Scheme 35

Feed both cutting wire ends -3- into the awl -2- and pull it in.

Place the cutting wire all the way around under the rear window as illustrated.

Scheme 36

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.

Scheme 37

Insert the ends of the cutting wire -1- into the spool -2-.

Tension the cutting wire using the spool -1- and insert the plastic film -2- taken from the VAS 6452 to protect the wire and the rear shelf.

Scheme 38

Cut the first section open, while doing this, the wire is guided into the integrated roller -arrow- on the spool.

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.

Scheme 39

Move the reel device and the guide awl as illustrated and cut free the section along the D-pillar.

Scheme 40

Move the reel device and the guide awl as illustrated.

Cut free the windshield further up to about the center.

Scheme 41

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

Scheme 42

Move the spool upward and insert the guide awl as illustrated.

Scheme 43

Cut free the windshield along the D-pillar upward.

Scheme 44

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.

Scheme 45

Remove the window glass using 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.

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

Preparations for the installing the rear window

Note. When reusing the undamaged window, cut rest of adhesive material on window and flange with Electric Cutter V.A.G 1561 A and Scraper (25 mm) 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.

With new window

Clean the adhesive surface all the way around with cleaning solution D 009 401 04.

Apply the glass/paint primer D 009 200 02 as described.

Applying primer

Apply the glass/paint primer -3- evenly over the adhesive surface on the window glass -4- in a single wiping motion using the applicator -2-.

Beginning applying with saturated felt.

1. Curing time 10 minutes

Window flange

If the windshield flange was damaged, then it must be repainted and if necessary, corrosion protected.

Clean the repaired area with cleaning solution D 009 401 04 and then apply glass/paint primer D 009 200 02.

Installation

Note. 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. Glass/paint primer
3. Window

1. Dimension -a- = 8 mm ±2 mm
2. Dimension -b- = 12 mm 2 mm
3. Dimension -c- = note spacing dimensions to window edge. Refer to item 2 .

Position the entire nozzle surface -2- on the window.

1. Application direction -arrow- for adhesive bead -1-.

Apply adhesive sealing material all around.

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

Insert the rear window into window opening using suction cups.

Center window along sides.

Pay attention to the distance to the roof. Refer to item 1 .

Observe minimum curing time. Refer to MINIMUM CURING TIMES .

Scheme 46

1. Door Window The door panel. Refer to «Removal and Installation»(/audi/a4/b8-2007-2012/remont/exteriorinterior-trim/#interior-trim-sedan) and the speaker are removed. Refer to «Removal and Installation»(/audi/a4/b8-2007-2012/remont/communication-devices/#communication-sedan) -- To remove, release catches -arrow- from coupling plate -2- with a screwdriver and pull window -1- in window guide up slightly. -- Tip window forward and remove it upward from door.
2. Window Regulator The window regulator remains installed inside the door.

Door Window, Releasing

Scheme 47

Run door window down.

Using a screwdriver, press coupling plate -3- outward to release through cut-out in window guide -1- and hole in door window -2-.

Remove window upward from coupling plate.

Tilt the window forward and pull it straight upward and out of the window guide.

Door Window, Inserting

Scheme 48

Insert door window -1- diagonally toward front in door window guide.

Align window in front and rear window guides and slide it down.

Press window down into coupling plate.

This engages coupling plate in window.

Scheme 49

1. Door Window Door trim removed. Refer to «Removal and Installation»(/audi/a4/b8-2007-2012/remont/exteriorinterior-trim/#interior-trim-sedan) . Loosen the door window frame trim near the C-pillar trim. Refer to «Removal and Installation»(/audi/a4/b8-2007-2012/remont/exteriorinterior-trim/#interior-trim-sedan) . C-pillar trim removed. Refer to «REAR B-PILLAR AND C-PILLAR TRIM»(/audi/a4/b8-2007-2012/remont/mirrors/#exterior-equipment-sedan) . Remove the door panel. Refer to «DOOR INNER PANEL COVER»(/audi/a4/b8-2007-2012/remont/windows/#rear-doors-sedan) . The power window motor and speaker are removed. Lower the door window into the removed position, refer to item 1 . Push the clamping pins through the bolts and push the expanding sleeve through the glass. Tip the window slightly to the rear inside the door and lift it up and out. Installation occurs in reverse order.
2. Window Regulator
3. Bolts Two-part The bolts can be re-used.

SPECIAL TOOLS

Special tools and workshop equipment required

Scheme 50

Scheme 51

Scheme 52

Scheme 53

Scheme 54

Scheme 55

Scheme 56

Scheme 57

Scheme 58

Scheme 59

Scheme 60

Scheme 61

1. Window Repair Kit VAS 1993 or VAS 6092
2. Cutting Tool Kit VAS 6452
3. Wire Spool VAS 6452/1
4. Cutting Tool Kit Wire VAS 6452/2
5. Cutting Tools For Glass V.A.G 1351
6. Pull Handle V.A.G 1351/1
7. Suction Lifter V.A.G 1344
8. Electric Cutter V.A.G 1561A
9. Angled Blade V.A.G 1561/10
10. Universal Cutting Blade V.A.G 1561/11
11. Scraper (15+25 mm) V.A.G 1561/7+8
12. Double Cartridge Gun VAS 5237
13. Cartridge Gun V.A.G 1628
14. Cartridge Heater V.A.G 1939A

See also:
• [For engine(s) CAEB, CALA, CCBA] Removal and Installation
• ROOF TRIM STRIP OVERVIEW
• [For engine(s) CAEB, CALA, CCBA] Removal and Installation
• Removal and Installation
• [For engine(s) CAEB, CALA, CCBA] Removal and Installation
• PLENUM CHAMBER COVER
• Removal and Installation
• Removal and Installation
• REAR B-PILLAR AND C-PILLAR TRIM
• DOOR INNER PANEL COVER
• MINIMUM CURING TIMES
• FLUSH-BONDED WINDOWS => Minimum curing time (--> curing time)