Glass, Window Regulators (coupe) Audi A5 I

MATERIALS AND TOOLS

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. Window 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

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

First, clean paint surfaces with a dry cloth. Remove residual adhesive with adhesive remover D 002 000 10.

Plastic trim

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

Scheme 1

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 field of sight. For further details on use, refer to operating instructions enclosed with each kit.

MINIMUM CURING TIMES

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 ASSEMBLY OVERVIEW

Note. On vehicles equipped with lane assist, the camera must be recalibrated if the windshield has been replaced. Refer to General Information .

Scheme 2

1. Windshield Distance to roof dimension -a- = 4.5 mm. Align the side distance -c-.
2. Adhesive sealing material Observe minimum curing time. Refer to «MINIMUM CURING TIMES»(/audi/a5/i-2007-2011/remont/windows/#glass-window-regulators-coupe__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 minimum curing time is complete (3 hours).

Water Deflector, Removing

Scheme 3

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 4

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

Scheme 5

1. Side Window Roof trim molding and side trim molding removed. Refer to «ROOF TRIM MOLDING»(/audi/a5/i-2007-2011/remont/mirrors/#exterior-equipment-coupe__roof-trim-molding) . When installing a new window, first press it onto the >>C-pillar<< using the securing pin and then insert it completely in the window opening. If a removed window is reinstalled, secure it to the C-pillar using adhesive tape.
2. Adhesive sealing material
3. Spacer 3x
4. Securing pin No replacement part Is cut through when removing window.

Undamaged side window, removing

Remove the door seal in the >>A-pillar<< and side window area.

Remove the side trim molding and roof molding.

Scheme 6

Route the cutting cord 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 wire 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 1561/10 (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 and Paint Primer D 009 200 02 all around in adhesive area.

1. Drying time 10 minutes.

Side Window, 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 7

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 or through the remaining bead.

Position complete surface of nozzle -2- onto window.

Scheme 8

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 Adhesive DH 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.

Press the new window in with the securing pin on the C-pillar and then insert it in the window opening and secure it to the B-pillar using adhesive tape.

On windows without a securing pin, align the window lengthwise to the edge on the side panel -arrow- and then insert it into the cut-out for the window.

Scheme 9

Install the roof trim strip and lower trim strip into the clips on the side panel and then center the glass.

Install the door seal to the B-pillar.

Observe minimum curing time. Refer to MINIMUM CURING TIMES .

Scheme 10

1. Rear Window Distance -a- to roof = 2.5 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 = 15 mm Dimension c = 24 mm Dimension e = 16 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.

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 adhesive tape.

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

Poke the awl -2- through the bead of adhesive from the inside to the outside as illustrated.

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

Scheme 11

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

Route cutting wire around rear window under the glass as shown in the illustration.

Scheme 12

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

Scheme 13

Insert an additional guide awl 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.

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

Scheme 14

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

Scheme 15

Cut the window free first in the lower area.

Scheme 16

Cut the lower window at the D-pillar free

Scheme 17

Position the guide ring as shown and cut upward further in the area of the D-pillar.

Move the spool and the guide awl as illustrated and cut free the section along the opposite lower D-pillar.

Scheme 18

Move the reel device as illustrated and install the guide awl.

Scheme 19

Cut top of window free.

Move the reel device as illustrated.

Scheme 20

Cut the window free on the right upper corner.

Scheme 21

Move the window glass over to the left corner of the window and cut the window free.

Scheme 22

Move the left reel device to approximately the center of the window as illustrated and mount the guide awl.

Scheme 23

Cut the window free along the top to approximately the center of the window.

Scheme 24

Move the right on the right side reel device over the left one as illustrated and cut free the window completely.

Scheme 25

Lift the window out of the rear lid using the 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 window all around in adhesive area using Cleaning Solution D 009 401 04.

Apply the glass/paint primer D 009 200 02.

Applying primer

Scheme 26

Apply the glass/paint primer -3- to the adhesive surface on the glass -4- evenly and in a single stroke using the applicator -2-.

Beginning applying with saturated felt.

1. Drying time 10 minutes

Window flange

If the window flange was damaged, paint structure must be recreated and if necessary, perform corrosion protection measures.

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

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

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- = pay attention the distance to the edge of the glass.

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

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

Apply adhesive sealing material all around.

Scheme 27

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

Insert the rear window into window cut-out using suction cups.

Center window along sides.

Note distance to upper lid edge = 2.5 mm.

Observe minimum curing time. Refer to MINIMUM CURING TIMES .

Scheme 28

1. Door
2. Bolt 9 Nm
3. Window Regulator Adjusting, refer to «DOOR WINDOW, ADJUSTING»(/audi/a5/i-2007-2011/remont/windows/#glass-window-regulators-coupe__door-window-adjusting)
4. Door window Removing and Installing, refer to «DOOR WINDOW»(/audi/a5/i-2007-2011/remont/windows/#glass-window-regulators-coupe) . Adjusting, refer to «DOOR WINDOW, ADJUSTING»(/audi/a5/i-2007-2011/remont/windows/#glass-window-regulators-coupe__door-window-adjusting)
5. Bolt 9 Nm
6. Window regulator motor

Scheme 29

1. A - Door window to A-pillar Gap dimension -a - = 5.3 mm Gap dimension -b- = 2.2 +/- 1.5 mm -1- Door window Adjusting, refer to «DOOR WINDOW, ADJUSTING»(/audi/a5/i-2007-2011/remont/windows/#glass-window-regulators-coupe__door-window-adjusting)
2. B - Door window to the front of the roof Gap dimension -a - = 6.2 mm Gap dimension -b- = 5.1 +/- 1.5 mm -1- Door window Adjusting, refer to «DOOR WINDOW, ADJUSTING»(/audi/a5/i-2007-2011/remont/windows/#glass-window-regulators-coupe__door-window-adjusting)
3. C - Door window to the back of the roof Gap dimension -a - = 6.7 mm Gap dimension -b- = 3.0 +/- 1.5 mm -1- Door window Adjusting, refer to «DOOR WINDOW, ADJUSTING»(/audi/a5/i-2007-2011/remont/windows/#glass-window-regulators-coupe__door-window-adjusting)

DOOR WINDOW, ADJUSTING

Note. To adjust the door glass, use the Side Window Installation Tool V.A.G 1739 and the Torx T25 screwdriver T10248.

Special tools and workshop equipment required

Scheme 30

Scheme 31

Scheme 32

1. Gauge T10391
2. Socket T10058
3. Side Window Installation Tool V.A.G 1739

Lateral adjustment

Note. Adjustment dimensions, refer to DOOR WINDOW GAP DIMENSIONS .

Scheme 33

1. A - Possible adjustment - Door bottom, rear For positioning the upper edge of the door window on the seal in the roof area accessible from outside, it is not necessary to remove the door trim. -1- Adjusting pins -5- Door window -- To adjust, loosen the locking nut -2- and rotate the adjusting pins -1- using a Torx socket wrench. Turn left - the door window rotates outward. Turn right - the door window rotates inward. Tighten the locking nut after adjusting. -- Tighten the locking nut -2- after adjusting it. -2- Locking nut - 9 Nm Door -3- -4- Window regulator
2. B - Possible adjustment - Door top, rear For sliding the door window in the door window recess outward or inward Accessible after removing the door trim «Removal and Installation»(/audi/a5/i-2007-2011/remont/exteriorinterior-trim/#interior-trim-coupe) . -1- Adjusting pins -5- Door window -- To adjust, loosen the locking nut -2- and rotate the adjusting pins using a Torx socket wrench. Turn left - the door window rotates outward. Turn right - the door window rotates inward. -- Tighten the locking nut -2- after adjusting it. -2- Locking nut - 9 Nm Door -3- -4- Window regulator
3. C - Possible adjustment - door top, front The front window regulator is stationary, it cannot be adjusted. -3- - door -5- - Door window -6- - Window regulator nut - 9 Nm
4. D - Possible adjustment - door bottom, front The front window regulator is stationary, it cannot be adjusted. Door -3- -6- Window regulator nut - 9 Nm

Height adjustment

Note. Adjustment dimensions, refer to DOOR WINDOW GAP DIMENSIONS .

Scheme 34

1. A - Possible adjustment - door bottom, rear For positioning the upper edge of the door window on the seal in the rear roof area Accessible through the holes on the bottom edge of the door. The door trim does not need to be removed. -1- Window regulator -2- Adjusting screw -- To adjust the height, turn the adjusting screw -2- using a 4 mm hex socket wrench. 1 turn = 1 mm adjustment -3- Door window
2. B - Possible adjustment - door bottom, front For positioning the upper edge of the door window on the seal in the front roof area Accessible through the holes on the bottom edge of the door. The door trim does not need to be removed. -1- Window regulator -3- Door window -4- Adjusting screw -- To adjust the height, turn the adjusting screw -4- using a 4 mm hex socket wrench. 1 turn = 1 mm adjustment

Scheme 35

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

The exterior mirror is moved. Refer to Removal and Installation .

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

Scheme 36

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 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-.

Peel the sensor film -2- carefully off the rain/light recognition sensor -G397- -1-.

Scheme 37

Clean the surface with cleaning solution D 009 401 04.

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

Scheme 38

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 39

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 40

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

Scheme 41

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 42

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 43

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 [For engine(s) CAUA, CAEB, CALA] Wiper/Washer Systems .

Remove the plenum chamber cover. Refer to PLENUM CHAMBER COVER - VEHICLES FROM JUNE 2008 .

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

Remove the interior rearview mirror Removal and Installation .

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

From the wire spool VAS 6452/1, pull out approximately 6.5 meters 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 44

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 45

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

Scheme 46

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

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

Scheme 47

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

Scheme 48

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 49

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 50

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

Cut free the windshield up to about the center.

Scheme 51

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

Scheme 52

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

Scheme 53

Cut free the windshield along the A-pillar upward.

Scheme 54

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 55

Remove the windshield from the vehicle with the suction cups.

Preparations for installing the windshield

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.

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

With new window

Clean adhesive surfaces 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

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 and if necessary, corrosion protected => Audi Paint Handbook.

First clean the corrected area with cleaning solution D 009 401 04 and then apply glass/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

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, item 2 2 .

Position complete surface of nozzle -2- onto window.

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

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

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, item 1 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 .

Scheme 56

Proceed as follows

Remove the door trim panel. Refer to Removal and Installation .

Remove the sealing plugs -2- and -4-.

Run the door window down until the bolts in the opening are visible.

Remove the bolts -1- but only loosen the bolt -5-.

Note. Remove the rear bolt -1- completely. Otherwise, the door window cannot be removed.

Tilt the rear door window -3- toward the outside out of the mount in the clamping brackets.

Remove the door window upward out of the clamping bracket and remove it from the door -arrow-.

INSTALLING

1. Gap dimensions, refer to «DOOR WINDOW GAP DIMENSIONS»(/audi/a5/i-2007-2011/remont/windows/#glass-window-regulators-coupe) .
2. Tightening specifications, refer to «WINDOW REGULATOR MOTOR AND WINDOW REGULATOR ASSEMBLY OVERVIEW»(/audi/a5/i-2007-2011/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system-coupe) .

Install in reverse order of removal. Note the following

Insert the door window forward into the door window guide diagonally and then rotate it back into the door shaft.

Carefully side the door window parallel down into the clamping brackets. Make sure the door window in the front window guide does not slip out.

Press the door window down into the clamping brackets.

Note. Before installing the rear bolt, make sure the door window is seated in the clamping bracket mount.

Tighten the bolts.

Adjust the door window. Refer to DOOR WINDOW, ADJUSTING .

SPECIAL TOOLS

Special tools and workshop equipment required

Scheme 57

Scheme 58

Scheme 59

Scheme 60

Scheme 61

Scheme 62

Scheme 63

Scheme 64

Scheme 65

Scheme 66

Scheme 67

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. Window 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

See also:
• General Information
• ROOF TRIM MOLDING
• Removal and Installation
• Removal and Installation
• [For engine(s) CAUA, CAEB, CALA] Wiper/Washer Systems
• PLENUM CHAMBER COVER - VEHICLES FROM JUNE 2008
• WINDOW REGULATOR MOTOR AND WINDOW REGULATOR ASSEMBLY OVERVIEW
• MINIMUM CURING TIMES
• DOOR WINDOW, ADJUSTING
• DOOR WINDOW