Audi A4: Windshield

Overview - Windshield

1 -  Windshield

• Removing and installing. Refer to → Chapter "Windshield, Removing and Installing".
• Distance to roof: Dimension -c- = 2.5 mm
• Distance to A-pillars: Dimension -e- = greater than 3 mm; center if necessary

2 -  Adhesive Bead

• Observe minimum curing times. Refer to → Chapter "Minimum Curing Times for Bonded Windows".
• Different distances to window edge:

• Dimension -a- = 7 mm
• Dimension -b- = 7.5 mm
• Dimension -d- = 9 mm

• Adhesive bead thickness.

3 -  Windshield Frame

4 -  Plenum Chamber Cover Frame

• Windshield component
• No replacement part
• With a new windshield, remove the protective molding before installing the cowl panel trim. Refer to → Fig. "Protective Molding, Removing".

5 -  Plenum Chamber Cover

• Insert in the frame -4-.
• Only press on until it stops after the minimum curing time for the adhesive has elapsed.

6 -  Cover Profile

• Replace if reusing an undamaged windshield
• Cover profile, mounting on undamaged windshield. Refer to → Anchor

7 -  Clamping Strip

• For the drip rail

8 -  Drip Rail

• Removing and installing. Refer to → Chapter "Drip Rail, Removing and Installing".

Protective Molding, Removing

- For a new windshield -3-, the protective molding -1- must first be removed from the frame -2- before assembling the plenum chamber cover.

Windshield, Removing and Installing

• Follow repair instructions. Refer to → Chapter "Repair Information".
• The following components must be replaced after removal. Refer to → Chapter "Overview - Windshield".
• Depending on the equipment version, the following additional work must be performed.
• Required tools and materials for removal and installation. Refer to → Chapter "Required Tools and Materials for Removal and Installation".

Removing

- Remove the plenum chamber cover. Refer to → Chapter "Plenum Chamber Cover, Removing and Installing".

- Remove the sun visors and the sun visor center support. Refer to → Body Interior; Rep. Gr.68; Equipment; Overview - Sun Visors.

- Remove the interior rearview mirror. Refer to → Body Interior; Rep. Gr.68; Interior Rearview Mirror; Interior Rearview Mirror, Removing and Installing.

- Remove the rain/light recognition sensor. Refer to → Electrical Equipment; Rep. Gr.92; Windshield Wiper System; Rain/Light Recognition Sensor, Removing and Installing.

- Remove the left and right A-pillar trim panels. Refer to → Body Interior; Rep. Gr.70; Vehicle Interior Trim Panels; A-Pillar Trim Panel, Removing and Installing.

- Disconnect the connectors, if equipped.

  CAUTION

Risk of injury to the hands and eyes from glass fragments.

Getting cut is possible.

- Wear protective eyewear.

- Wear safety gloves.

- Unroll approximately 6.5 meters (7.1 yards) of cutting wire (approximately six turns) with the -VAS6452/1- and cut it.

- To prevent any damage, cover the area where the awl comes out at the bottom of the body flange with adhesive tape -1-.

- Working from the inside outward, pierce the adhesive bead in this area using the awl -2-.

- Thread both cutting wire ends -3- into the awl and pull it toward the inside.

- Place the cutting wire all the way around under the windshield.

• The wire ends must not be twisted on the adhesive bead pass-through -arrow-.

- Mount both reel devices on the inside of the glass.

- Insert the cutting wire end -1- into the reel device -2-.

- Tension the cutting wire and place the protective film -2- between the instrument panel and the cutting wire.

- Cut the first section free. This will guide the cutting wire into the integrated idler roller -arrow- on the reel device.

- Insert an additional guide awl -2- into the adhesive bead and secure it to the window glass with the suction cup to make sure that the cutting wire runs as close to the glass as possible.

- If necessary, move the protective film -3- along with the wire and continue cutting the window glass free with the reel device -1-.

- Move the reel device and the guide awl and cut the area at the A-pillar free.

- Move the reel device and guide awl up to the center of the glass.

- Cut the window glass free up to the center of the glass.

- Use the second reel device to cut the lower section of the window glass free.

- Move the reel device upward and insert the guide awl.

- Cut the window glass out by moving upward along the A-pillar.

- Move the reel device over the center of the window glass and over the first reel device and cut the windshield completely free at the upper edge.

- Remove the windshield from the opening for the window using the -VAG1344-.

Installing

- Installation instructions. Refer to → Chapter "Required Tools and Materials for Removal and Installation".

- Prepare the undamaged window glass for installing. Refer to → Chapter "Undamaged Window Glass, Preparing for Installation".

Cover Profile, Mounting on Undamaged Windshield:

- Before installing the new cover profile, remove the rest of the old one -2- from the windshield -1- using a commercially available glass scraper.

TIP

The rest of the old glass adhesive bead -3- serves as an installation marker for the new cover profile.

- Prepare the new window glass for installation. Refer to → Chapter "New Window Glass, Preparing for Installation".

- Prepare the body flange for installation. Refer to → Chapter "Body Flange, Preparing for Installation".

- Insert the windshield into the window opening using two suction lifters and align it on the sides.

• Distance from the window edge to the roof frame -Item 1-.
• Secure the window to the top of the roof with adhesive tape.

- First remove the protective molding from the frame before installing the plenum chamber cover. Refer to → Fig. "Protective Molding, Removing".

- Observe minimum curing times. Refer to → Chapter "Minimum Curing Times for Bonded Windows".

Further installation is performed in reverse order of removal, while noting the following:

- Versions with driver assistance systems front camera: Recalibrate the camera. Refer to → Suspension, Wheels, Steering; Rep. Gr.44; Driver Assistance Systems Front Camera; Driver Assistance Systems Front Camera, Calibrating.

- Versions with Matrix LED headlamp: calibrate the Matrix LED headlamp. Refer to → Electrical Equipment; Rep. Gr.94; Headlamp.

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