Glass, Window Regulators (roadster) Audi TT 8J

Scheme 41

1. Windshield Distance to roof dimension -a- = 2 mm. Even out side distance dimension -c- = 3 mm.
2. Adhesive sealing material Observe minimum curing time «FLUSH-BONDED WINDOWS»(/audi/tt/8j-2006-2010/remont/windows/#glass-window-regulators-roadster) . Apply adhesive directly near window molding or lower molding. Dimension -d- = 8 mm +/- 2 mm Dimension -e- = 23 mm +/- 2 mm
3. Molding To remove, pull off of window edge. Before installing, completely remove adhesive residue from molding using a window scraper. Cut adhesive bead back from window adhesive but do not remove completely. Clean adhesive surface with Cleaning Solution -D 009 401 04-. CAUTION: Do not apply any bonding agents to the cut adhesive bead. Apply Bonding Agent -D 009 200 02- to adhesive surface and let dry 10 minutes.
4. Plenum chamber cover molding No replacement part With a new window, protective piping must first be removed before installing plenum chamber cover.
5. Plenum chamber cover Press into retaining strip only after window adhesive curing time is complete (3 hours).

Scheme 42

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

Scheme 43

1. Windshield Distance to roof dimension -a- = 2 mm. Even out side distance dimension -c- = 3 mm.
2. Adhesive sealing material
3. Spacer Bond the same number in the same positions as on the removed window.
4. Plenum chamber cover molding No replacement part With a new window, protective piping must first be removed before installing plenum chamber cover.
5. Plenum chamber cover Press into retaining strip only after window adhesive curing time is complete (3 hours).

Scheme 44

1. Side Window When installing, press in window with securing pin at >>C-pillar<<, then insert in window opening and secure with pop rivets in >>B-pillar<< area. If a removed window is reinstalled, window must be secured to >>C-pillar<< with adhesive tape.
2. Pop rivet To remove side window, drill out rivet heads and drive out rivet shafts.
3. Retaining clip
4. Roof trim molding Before roof trim molding can be removed from the clips, pop rivets in upper door area must first be removed. Refer to «ROOF TRIM MOLDING»(/audi/tt/8j-2006-2010/remont/mirrors/#exterior-equipment-roadster__roof-trim-molding) .
5. Securing pin No replacement part Is cut through during window removal

REAR WINDOW ASSEMBLY OVERVIEW

Scheme 45

1. Rear Window Distance -a- to upper lid edge = 2 mm Even out distance -b- to side lid edge = 2.5 mm. Before removing, disconnect all electrical connectors and secure to inside center of window with adhesive tape. When installing, center window all around in window opening.
2. Adhesive sealing material Apply all around between adhesive stopper profiles Bead width = 8 mm +/- 2 mm Bead height = 12 mm +2 mm
3. Connector Disconnect when removing window. Clipped into lid flange.
4. Adhesive stopper profile Apply window adhesive between profiles.

Undamaged Rear Window, Removing

Remove rear lid trim. Refer to Removal and Installation .

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

DOOR WINDOW, ADJUSTING

Special tools and workshop equipment required

1. Template T40038/7
2. Side window installation tool V.A.G 1739 and screwdriver Torx T25T10248

Height Adjustment

Note. Door trim must not be removed for height adjustment.

Height adjustment, checking DOOR, ADJUSTING => Adjusting with Template T40038/7

Scheme 46

1. Rear height stop Completely lower the window regulator. -- To adjust height, guide a hex socket wrench and 5 mm socket into adjusting sleeve from underside of door through door plate. -- Adjust stop up or down accordingly. NOTE: One complete revolution of the adjusting sleeve equals an adjustment distance of 1 mm.
2. Front height stop It is adjusted as with the rear height stop.

Side Adjustment

Adjustment, checking, refer to DOOR, ADJUSTING => Adjusting with Template T40038/7

Scheme 47

1. Window regulator Removing and installing, refer to «WINDOW REGULATOR»(/audi/tt/8j-2006-2010/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system-roadster)
2. Door
3. Nut 9 Nm
4. Nut 9 Nm
5. Collar screw -- For a lateral adjustment, loosen the upper or lower nuts -3- with the V.A.G 1739 and unscrew or screw in the upper or lower collar screw accordingly.

FLUSH-BONDED WINDOWS

Special tools and workshop equipment required

1. Removal Kit for Flush-Bonded Windows V.A.G 1474 A or 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 1939 A
7. Window cutter V.A.G 1561 A
8. Cutting blade (58 mm) V.A.G 1561/2
9. Cutting blade (U-shaped) V.A.G 1561/3
10. Scraper (25 mm) V.A.G 1561/8
11. Cutting blade, bent at right angle V.A.G 1561/10
12. Double cartridge gun VAS 5237
13. Spooling tool V.A.G 1654 A
14. Window Repair Kit VAS 6092

Servicing windows with Window Repair Kit VAS 6092

1. Windshields with stone damage can be repaired with the Window Repair Kit VAS 6092.
2. These damaged areas must not exceed a certain dimension or lie within the driver's field of sight.
3. For further details on use, refer to operating instructions enclosed with each kit.

Minimum Curing Times

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.

WINDSHIELD

Windshield, Removing

Remove windshield wiper arms. Refer to [For transmission(s) 02E] [For engine(s) CBRA, BPY, CETA, CCTA, CEPB, CDMA] Removal and Installation .

Remove cowl panel trim.

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 .

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

Scheme 48

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

Lay cutting cord underneath and all around inside of windshield.

Scheme 49

Tighten end of cutting cord at bolt to wiper arm mounting -arrow-.

Scheme 50

Slide the cover for Audi A4 dash panel V.A.G 1474/13 between the 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 51

Move spooling tool as shown and attach relay pulley.

Scheme 52

1. 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 53

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

Scheme 54

1. Route cord as shown.

Slide Cover for Dash Panel V.A.G 1474/7 between windshield and headliner.

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

Remove idler pulley and continue cutting window free.

Scheme 55

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.

Preparations for Installing Windshield

When reusing the undamaged window, cut rest of adhesive material on window and flange with V.A.G 1561 A and 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 window all around in adhesive area using Cleaning Solution D 009 401 04.

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

Applying Primer

Scheme 56

Apply 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. Apply primer in center of adhesive bead.
3. 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.

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 57

1. Adhesive sealing material
2. Primer
3. Window

1. Dimension -a- = 8 mm
2. Dimension -b- = 12 mm
3. Dimension -c- = note varying spacing dimensions to window edge «WINDSHIELD ASSEMBLY OVERVIEW - COUPE»(/audi/tt/8j-2006-2010/remont/windows/#glass-window-regulators-roadster) .

Position complete surface of nozzle -2- onto window.

Scheme 58

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

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

Scheme 59

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

Using double suction cups, install the windshield.

Center window along sides.

1. Spacing between edge of window and roof frame must be 5 mm +/- 0.5 mm .

Slide adjusting wedge -1- as shown between clamping strip -5- and body flange.

Scheme 60

Before installing plenum chamber cover, first remove protective profile -2- from clamping strip.

Observe minimum curing time FLUSH-BONDED WINDOWS .

A-PILLAR SEAL

Removing

Scheme 61

1. Guide rail To remove, drill out rivet heads -4- and drive out rivet shafts.
2. Sealing molding No replacement part
3. Sealing band Self-adhesive.
4. Pop rivet Quantity: 5
5. A-pillar seal Roof frame trim removed. Refer to «Removal and Installation»(/audi/tt/8j-2006-2010/remont/exteriorinterior-trim/#interior-trim-roadster) To remove, remove from guide rail. For easier assembly, coat seal with soapy solution. When installing, engage in guide rail as shown.

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

SIDE WINDOW

Undamaged Side Window, Removing

Remove door seal in side window area.

Drill out upper and lower rivet heads in >>B-pillar<< area on window and drive out rivet shafts.

Scheme 62

Pry roof trim molding -1- out of clips in side window area.

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 V.A.G 1351.

Use light sawing motions to pull the cutting cord forward in the direction of arrow -A-. Cut the lower adhesive bead on the side piece and the 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.

Remove glass pieces from adhesive material.

Bond flange all around with fabric reinforced adhesive tape.

Remove adhesive material (with glass residue) from window opening using V.A.G 1561A and 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 window all around in adhesive area using 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

After the preparatory work has been performed, cut nozzle tip as shown in illustration.

Scheme 63

1. Dimension -a- 12 mm

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. 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 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 in window with securing pin at C-pillar, then insert in window opening and secure with pop rivets in B-pillar area.

Observe minimum curing time FLUSH-BONDED WINDOWS .

REAR WINDOW

Gradually push a cutting wire through the adhesive bead from the inside to the outside with needle-nose pliers as shown.

Scheme 64

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

Loosen the hex bolt -arrow- on the rear lid hinge -1- and clamp the end of cutting wire -2- securely with it.

Scheme 65

Clamp the cutting wire in the spool.

After removing window, tighten bolt to 21 Nm.

Cut first area free.

Scheme 66

Move spooling tool as shown and position idler pulley on lower part of window.

Scheme 67

1. Wire run according to figure.

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

Remove idler pulley and continue cutting window free.

Scheme 68

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

Scheme 69

1. Wire run according to figure.

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

Remove idler pulley and continue cutting window free.

Scheme 70

Repeat procedure in upper and lower right part of window.

Cut glass completely free in this manner.

Remove window with double 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 V.A.G 1561A and V.A.G 1561/10 (with stopper roll).

Preparations for Installing Rear Window

Note. When reusing the undamaged window, cut rest of adhesive material on window and flange with V.A.G 1561 A and 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

Scheme 71

Clean window in adhesive area between inner -1- and outer adhesive stopper profiles -2- using Cleaning Solution D 009 401 04.

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

Note. Ceramic application on window is not primer! It must be primed before the application of adhesive sealing material!

Applying Primer

Apply primer -3- with applicator -2- evenly in one stroke between adhesive stopper profiles on window -4-.

Beginning applying with saturated felt.

1. Apply primer over entire width between stopper profiles.
2. Drying time 10 minutes

Note. If the paint on the window flange is damaged when the rear window is removed, repair it according to the Audi paint handbook.

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

Rear Window, Installing

Scheme 72

1. Rear window Insert in window opening with double suction cups.
2. Inner adhesive stopper profile Prevents adhesive from touching distributing wire.
3. Outer adhesive stopper profile Prevents adhesive from leaking to outside.

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. Primer
3. Window

1. Dimension -A- = 8 mm +/- 2 mm
2. Dimension -b- = 12 mm 2 mm

Position complete surface of nozzle -2- onto window.

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

Apply adhesive sealing material all around between adhesive stopper profiles.

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

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

Center window along sides.

Note distance to upper lid edge = 2 mm.

Observe minimum curing time FLUSH-BONDED WINDOWS .

FRONT DOOR WINDOW

Special tools and workshop equipment required

1. Suction lifter V.A.G 1344

Scheme 73

1. Door window Removing -- Door trim removed. Refer to «Removal and Installation»(/audi/tt/8j-2006-2010/remont/exteriorinterior-trim/#interior-trim-roadster) . -- Front and rear inner door plate cover or speaker removed -- Run window down until bolts -2- and -5- in door opening are accessible -- Remove bolt -6-, only loosen bolt -2-. -- Tip window forward and remove it upward from window shaft. Installing: -- Insert in window regulator in reverse sequence. Press window back into window guide and tighten bolts -2- and -6- slightly. -- Run window up into door seal, this centers the window in the door opening. -- Using Suction Lifter V.A.G 1344, press window up into seal on roof and forward into seal on >>A-pillar<< and hold in this position. -- A second technician must tighten bolts -2- and -6- to the specification from inside of vehicle. -- Perform height or side adjustment if necessary. Refer to «DOOR WINDOW, ADJUSTING»(/audi/tt/8j-2006-2010/remont/windows/#glass-window-regulators-roadster__door-window-adjusting)
2. Front bolt 7 Nm
3. Nut 9 Nm
4. Front clamping brackets
5. Window regulator Removing and installing, refer to «WINDOW REGULATOR»(/audi/tt/8j-2006-2010/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system-roadster)
6. Rear bolt 7 Nm
7. Thrust piece No replacement part

FRONT INNER DOOR PLATE COVER

Removing

Scheme 74

Cover -1- and cover -3- are each radio-dependent.

Before installing cover, check butyl cord -2- and correct if necessary.

To install, insert centering pin -arrow- in cover -1- and press cover into inner door plate.

REAR INNER DOOR PLATE COVER

Removing

Scheme 75

1. Rear cover -- Door trim removed «Removal and Installation»(/audi/tt/8j-2006-2010/remont/exteriorinterior-trim/#interior-trim-roadster) . -- To remove, release retaining tabs -arrows- on cover using a thin object.
2. Door inner panel
3. Seal Before installation, check the cover seal and replace if necessary

SPECIAL TOOLS

Special tools and workshop equipment required

Scheme 76

Scheme 77

Scheme 78

1. Removal Kit for Flush-Bonded Windows V.A.G 1474 A or 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 1939 A
7. Window cutter V.A.G 1561 A
8. Cutting blade (58 mm) V.A.G 1561/2
9. Cutting blade (U-shaped) V.A.G 1561/3
10. Scraper (25 mm) V.A.G 1561/8
11. Cutting blade, bent at right angle V.A.G 1561/10
12. Double cartridge gun VAS 5237
13. Spooling tool V.A.G 1654 A
14. Template T40038/7
15. Side window installation tool V.A.G 1739 and screwdriver Torx T25T10248

Scheme 79

Scheme 80

See also:
• ROOF TRIM MOLDING
• Removal and Installation
• DOOR, ADJUSTING => Adjusting with Template T40038/7
• WINDOW REGULATOR
• [For transmission(s) 02E] [For engine(s) CBRA, BPY, CETA, CCTA, CEPB, CDMA] Removal and Installation
• Removal and Installation
• FLUSH-BONDED WINDOWS
• FLUSH-BONDED WINDOWS
• DOOR WINDOW, ADJUSTING