Glass, Window Regulators (Coupe): Other Audi S5 I facelift

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 40

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.

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 41

Scheme 42

Scheme 43

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 44

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»(ref-520145-S04777688542012123100000) . -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 45

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 46

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 47

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 48

Clean the surface with cleaning solution D 009 401 04.

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

Scheme 49

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 50

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 51

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

Scheme 52

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 53

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 54

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 55

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 56

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

Scheme 57

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 58

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

Scheme 59

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 60

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 61

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

Cut free the windshield up to about the center.

Scheme 62

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

Scheme 63

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

Scheme 64

Cut free the windshield along the A-pillar upward.

Scheme 65

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 66

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 67

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»(ref-520177-S19906784732012123100000) .
2. Tightening specifications, refer to «WINDOW REGULATOR MOTOR AND WINDOW REGULATOR ASSEMBLY OVERVIEW»(ref-520194-S22153146622012123100000) .

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 .