Removing and installing rear window - Saloon: Audi A4 B8

🧭 Before you start

Fits: Audi A4 B8 (8K, 2007–2015)

• Special tools named: V.A.G 1561/8

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• Always wear safety goggles and leather gloves when removing window. — Use wire reelVAS 6452/1 to reel off about 6.5 metres of cutting wire (corresponding to 6 turns) and cut off.
• The wire ends must not be twisted at the point where they pass through the adhesive bead (arrow). — Attach both reels to inside of window, as shown.
• Always wear safety goggles and leather gloves when removing window. — Protect body and interior against damage from glass splinters.
• The ceramic coating on the glass is not a primer.The glass must always be primed before applying adhesive sealant. — Apply glass/paint primerD 009 200 02 as described below.
• The cross-section of the adhesive bead is determined by the nozzle opening and the rate of application.

📋 Procedure

1. Unplug electrical connectors for heated rear window and window aerial, move towards centre of window and secure with adhesive tape.
2. ⚠ Always wear safety goggles and leather gloves when removing window. — Use wire reel VAS 6452/1 to reel off about 6.5 metres of cutting wire (corresponding to 6 turns) and cut off.
3. Mask over body flange with adhesive tape (1) to avoid damage where awl is pushed through at the bottom.
4. Thread both ends of cutting wire (3) into awl (2) and pull through to the inside.
5. Position cutting wire under glass all round rear window, as shown.

6. Position cutting wire around rear window (under window), as shown.
7. ⚠ The wire ends must not be twisted at the point where they pass through the adhesive bead (arrow). — Attach both reels to inside of window, as shown.
8. Insert end of cutting wire (1) into reel (2).
9. Tension cutting wire with reel (1) and insert plastic film (2) from removal kit VAS 6452 as protection between wire and rear shelf.
11. Cut clear the first area. While doing so, wire is guided into integrated idler pulley (arrow) on reel.
12. Additionally insert guide awl (2) into adhesive bead, as shown, and attach it to window using suction pad so that wire runs along window as close to the glass as possible.
13. Adjust reel and guide awl, as shown, and cut clear area on D-pillar.
14. Adjust reel and guide awl, as shown.
15. Continue cutting window clear up to around its centre.
16. Use second reel to cut clear bottom area of window.
17. Move reel up and insert guide awl, as shown.
18. Cut window clear upwards along D-pillar.
19. Adjust reel over centre of window and adjust via first reel as shown and cut window fully clear at top.
20. Remove window from window opening using suction lifters.
21. ⚠ Always wear safety goggles and leather gloves when removing window. — Protect body and interior against damage from glass splinters.
22. Remove glass fragments down to adhesive sealant.
23. Unplug electrical connectors for heated rear window and window aerial.
24. Mask flange all round with fabric-backed adhesive tape.
25. Cut through adhesive sealant (with glass fragments) in window opening using electric cutter V.A.G 1561A and offset blade V.A.G 1561/10 (with roller stop). [Note: Just before re-installing an undamaged window, use electric cutter V.A.G 1561 A and scraper (25 mm)V.A.G 1561/8 to cut back the remaining adhesive sealant on the window and flange to give a smooth surface, but do NOT remove completely. The remaining sealant is required as a base for better adhesion of the new adhesive sealant.]
26. ⚠ Keep bonding surface clean and free from grease. Do not cut back bonding surface until shortly before installation. Do not apply primer to bonding surface and do not use cleaning solution. — Clean all around bonding surface with cleaning solutionD 009 401 04.
27. ⚠ The ceramic coating on the glass is not a primer. The glass must always be primed before applying adhesive sealant. — Apply glass/paint primerD 009 200 02 as described below.
28. Use applicator (2) to apply glass/paint primer (3) evenly and in one movement to bonding surface on window (4).
29. Start application with fully soaked felt.
30. ⚠ Glass/paint primer is conductive and must not come into contact with bus bar of rear window heating. — If window flange has been damaged, paintwork structure must be repaired and, if necessary, anti-corrosion measures must be taken Audi Paintwork Guide.
31. Clean treated area with cleaning solutionD 009 401 04 and then apply glass/paint primerD 009 200 02. [Note: The cross-section of the adhesive bead is determined by the nozzle opening and the rate of application.]
32. Apply full surface of nozzle (2) to window.
33. Apply adhesive sealant all around window.
34. When reinstalling an undamaged window, apply adhesive to remaining adhesive bead.
35. Fit rear window into window opening using suction lifters.
36. ⚠ The rear window must be fitted within 15 minutes; otherwise the adhesive properties of the adhesive sealant will be impaired. — Align window glass so that spacing is equal on both sides.
37. Observe distance from roof = (value given in the factory table, not available here).
38. Note minimum drying time (see the separate procedure).

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