Removing and installing flush-bonded windows - general — AUDI

Tools

From the V.A.G 1747 Parting Tool set:

0 -
Take-up reel (upper roller)
1 -
Jockey pulleys
2 -
Awl
3 -
Locator for awl
4 -
Protective foils for dash panel
5 -
Wedge
6 -
Take-up reel (lower roller)
- supplied separately - V.A.G 1654

Note:

Use protective film V.A.G 1474/7 to protect the dash panel when removing the windscreen. The protective film in the parting tool set does not fit.

Cutting tool V.A.G 1351

Electric cutter V.A.G 1561

For broken windows, to detach glass residues and adhesive sealant from the window flange
Cutter for side and rear windows: 1561/1

Warning
When using the electric cutter to remove window panes, mask window cut-out with fabric-reinforced adhesive tape.
Cartridge gun V.A.G 1628
Double suction cup unit V.A.G 1344

Standard commercially available tools:

Carpet knife

Cartridge heater V.A.G 1939

Warning
Follow the manufacturer's safety and usage instructions when handling materials.
Materials

Designation · Part no.
Adjusting wedges for windscreen (x 2) · 893 845 631
Adjusting wedges for rear window (x 2) · 893.845.631 A
Cutting wire (50 m) · 443 845 955
1K adhesive sealant · DH 009 100 1) 3)
1K adhesive sealant · DH 009 100 03 1) 3) 4)
2K adhesive sealant · D 004 300 05 1) 2)
Activator · AMV 181 800 02
Glass primer/paint primer · D 009 200 02
Cleaning solution · D 009 401 04
Primer applicator · D 009 500 25
Adhesive remover · D 002 000 10

1
Observe waiting time => Page
64-5
.

2)
Use only for windscreens and side windows

3)
Heat according to manufacturer's instructions with cartridge heater V.A.G 1939

4)
Miniature 110 ml cartridge for sealing and/or for when the 300 ml cartridge is insufficient

Waiting time

Waiting time: Between bonding in the window and using vehicle.
During waiting time, vehicle must be left standing on a flat surface at room temperature ( > 15oC) .

Type of window · Vehicle · Adhesive sealant · Waiting time
Wind- · without airbag · / DH 009 100 · / 4 hours
window · with airbag · DH 009 100 · 16 hours
without airbag · / D 004 300 05 · / 1 hour
with airbag · D 004 300 05 · 4 hours
Side · DH 009 100 · 4 hours
window · D 004 300 05 · 1 hour
Rear windows · DH 009 100 · 4 hours

Warning
Vehicle is not safe to drive until waiting time has elapsed.
Removing contamination caused by adhesive sealant

Adhesive remover D 002 000 10 is the recommended cleaning agent. Always follow the safety instructions.

Warning
When cleaning from inside the vehicle passenger compartment, the window just fitted must not be pressed outwards.
Paint areas:

Clean painted surface with a dry cloth. Remove residual dirt with adhesive remover D 002 000 10 .

Plastic trims:

Allow adhesive sealant to set (approx. 1 hour) and then pull off.

1-adhesive sealant leak test

Note:

The leak test fulfils two functions:

Leakage check; re-seal if necessary => "Re-sealing windows".
The moisture causes the 1-pack adhesive sealant to form a skin and set more quickly.

Apply water to check for leaks.
Carry out a visual inspection from inside the vehicle.

Touching up windows with sealant

Allow leaking area to dry and then clean.
Apply and spread adhesive sealant on leaky area on exterior between window pane and panel flange.
Allow adhesive sealant to flash off.

Note:

The 100 ml miniature cartridge D 009 100 03- is recommended for touching up with sealant.