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

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 1

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»(ref-520177-S10755007142012123100000) . 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 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 MOLDING»(ref-520084-S25301141792012123100000) . 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 5

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 6

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 7

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 8

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 9

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 10

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 11

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

Scheme 12

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 13

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 14

Cut the window free first in the lower area.

Scheme 15

Cut the lower window at the D-pillar free

Scheme 16

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 17

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

Scheme 18

Cut top of window free.

Move the reel device as illustrated.

Scheme 19

Cut the window free on the right upper corner.

Scheme 20

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

Scheme 21

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

Scheme 22

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

Scheme 23

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

Scheme 24

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 25

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 26

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 27

1. Door
2. Bolt 9 Nm
3. Window Regulator Adjusting, refer to «DOOR WINDOW, ADJUSTING»(ref-520177-S32219639302012123100000)
4. Door window Removing and Installing, refer to «DOOR WINDOW»(ref-520177-S17197884422012123100000) . Adjusting, refer to «DOOR WINDOW, ADJUSTING»(ref-520177-S32219639302012123100000)
5. Bolt 9 Nm
6. Window regulator motor

Scheme 28

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»(ref-520177-S32219639302012123100000)
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»(ref-520177-S32219639302012123100000)
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»(ref-520177-S32219639302012123100000)