2007-10 Audi Q7

Photo by Edmunds.com

© 2011 National Glass Association. All rights reserved. Visit GlassMagazine.com for glass removal and replacement instructions for more than 450 vehicles. To sign up to receive the For Technicians Only e-bulletin, email FTO@glass.org.

Vehicle type: Four-door utility vehicle

NAGS numbers*: Windshield part numbers FW02637 solar, upper and lower molding, rain/light sensor; and FW02887 solar, upper and lower molding, rain/light sensor, lane departure warning system

Helpful tools or supplies: Rain sensor adhesive pad; wireout tools

Watch for: Wiper removal will pose a problem on the driver side. Audi seems to have made a mistake when designing the wiper system. The wiper is aluminum and the wiper post is steel, causing galvanic corrosion. This makes the separation difficult.

Also, the top, exposed edge of the windshield is extremely close to the pinchweld wall and will require special cutout procedures. Consider having a helper on hand. If you do not, and choose to cut out the top bead using a cold knife or power tool, this will mark and scratch the wall of the pinchweld. It will require priming and the use of an aftermarket molding to cover the primed surfaces. If you use this method, the type of molding used should be discussed with the customer prior to installation.

*With permission from National Auto Glass Specifications. Call NAGS at 800/551-4012 or visit http://glass.mitchell.com/.

A. Windshield

Preparation

1. Pre-inspect the vehicle, checking the operation of the mechanical devices. Before checking the operation of the rain sensor, make sure all the windows, doors and hood are closed. Sprinkle the rain sensor window with water, get in the vehicle, and close the door. Turn on the vehicle and wiper system. The wipers should clear the windshield and stop.

2. Cover the front seats, floorboards, dash and steering wheel with a clean drop cloth or disposable plastic covers. Note: Always wear eye and hand protection when working with glass. Make sure you have the right glass and moldings and that the urethane systems you are about to use are current. Windshield part numbers are FW02637 and FW02887.

3. Drape the fender with a fender cover and tape up any vulnerable areas on the vehicle to protect against possible damage. Tape up the defroster vents to prevent debris from falling into the openings.

4. This vehicle has a rain/light sensor built into the base of the rearview mirror. To remove the mirror and rain sensor, follow these steps:

• You do not need to remove the decorative cover on the base of the mirror in order to remove the mirror. Instead, separate the wire cover from the base and give the mirror a quarter-turn, counterclockwise.
  
• Disconnect the two wiring harnesses: one for the rain sensor and one for the light sensor.
• Note, after you have removed the windshield from the vehicle, it is recommended you also remove the rain sensor from the glass. See step 18.
  

5. Wiper removal will pose a problem on the driver side. Audi seems to have made a mistake when designing the wiper system. The wiper is aluminum and the wiper post is steel, causing galvanic corrosion. This makes the separation difficult.

6. Remove the windshield-wiper nut covers: two on the passenger side and one on the driver side.

7. Remove the windshield-wiper nuts using a 16-millimeter wrench or socket. Remove the passenger-side, two-armed wiper by depressing the joint. Hopefully, it will loosen.

8. The driver-side wiper base is under the hood, making it impossible to use a wiper puller.

To release, depress the wiper joint until the corrosion breaks loose. This can take a lot of time and effort to achieve. If this does not loosen the wiper, raise the wiper to a more vertical position by manually manipulating the wiper upwards. Note, adjustments must then be made later. Raise the wiper arm and wiggle the arm up and down and right to left to loosen it from the post. You might need to do this several times before it releases.

9. The top molding is a PAAS-style molding, but it is extremely close to the pinchweld wall, and will require special cutout procedures.

10. Pry the A-pillar moldings out of the retainer strip riveted to the A pillar. Use a plastic pry tool, door-pad tool or your fingers to pry the molding upwards out of the retaining strip.

11. Remove the cowl panel by removing the hood bulb seal from the front leading edge of the panel.

12. The glass edge of the cowl panel tucks into a lower retainer strip attached to the lower edge of the glass. This strip comes on the glass. Starting in the corner, use a plastic pry tool to get the cowl edge started, and then pry upwards along the entire lower edge.

13. Under the driver side of the cowl panel is an electrical connector that inserts into a receptor that secures it in place.

There is no need to disconnect the wiring harness, just slide it out of its holster and let it hang.

14. Put the cowl panel in a safe place. Note: Before beginning windshield removal, verify the new windshield is the correct one and the urethanes and primers are current. Never use outdated products as this could jeopardize the structural integrity of the vehicle and the safety of its passengers.

Removal

15. Before cutting out the windshield, remove contaminants from the glass and pinchweld to avoid making contact with the urethane.

16. Windshield cutout can pose a problem near the top. Follow these steps to handle this problematic cutout:

A. Option 1: With helper

• Make sure cutting blades are sufficiently sharp.
• Cut the side beads using a cold knife.
• Cut the bottom bead using a power-paddle cutout tool and water for lubricant.
• Apply vacuum cups to the windshield exterior and have your helper pull the glass downward. Use a cold knife with a padded or taped blade to cut out the top on one side. Repeat on the other side.

B. Option 2: Without helper

• Make sure cutting blades are sufficiently sharp.
• Cut the side beads using a cold knife.
• Cut the bottom bead using a power-paddle cutout tool and water for lubricant.Tape up the roof of the vehicle.
• Lip cutout wire under one of the top corners and cut out the top portion of the windshield, being careful not to scratch the roof or wall of pinchweld.
• Or, use a cold knife or power tool to cut the top bead. Note, this will mark and scratch the wall of the pinchweld and will require priming and the use of an aftermarket molding to cover the primed surfaces. If you use this method, the type of molding used should be discussed with the customer prior to installation.

17. Take the windshield out of the opening using a set of vacuum cups. Make sure the vacuum cups do not overlap a crack in the glass. Lift the glass and place it on a windshield stand or suitable workstation.

18. Remove the rain sensor from the windshield. To do so:

• Remove the aluminum retaining clip by pressing down on the clip just above the retaining wings.
• Use a hooked pick to pry out the wings of the clip and release it from the bracket.
• Repeat on the other side and retain the clip for reuse.

Installation

19. After cutting the windshield out, remove contaminants such as dirt, moisture and debris from the pinchweld. Clean the dashboard.

20. If using an aftermarket molding to cover scratches to the primed surfaces, make sure to dry fit the new glass to the opening. Mark your glass using a grease pencil or retention molding tape.

21. Place your vacuum cups on the new windshield in the appropriate location.

22. Set the windshield onto the old urethane.

23. With the windshield resting in the opening, make sure it is in the right spot.

24. Adjust both sides to the correct setting, marking the passenger side, then the driver side. Lift the glass and place it on a windshield stand or suitable workstation.

25. Follow the urethane manufacturer's recommendations for installation.

26. Clean the inside of the windshield using a urethane manufacturer-recommended product. Do not touch the bonding area of the windshield after cleaning, prepping or priming it.

27. Attach the rain sensor to the new windshield. To do so:

• Clean the glass area where the sensor will be mounted. Allow to dry thoroughly.
• Make sure the adhesive pad is warm and pliable.
• Attach a new, optically clear adhesive pad to the rain sensor lens and make sure there are no bubbles.
• Insert the lens into the bracket and press downward to make sure there are no bubbles that appear through the window on the opposite side of the glass.
• Reattach the retaining clip. Make sure there are no bubbles that appear in the outside lens window.

28. Wear powder-free Nitrile gloves to protect against harsh chemicals.

29. Apply the glass prep and primer following the urethane manufacturer's recommendations.

30. Using the tool of your choice, remove the original urethane bead, leaving 1 mm-2 mm of existing urethane on the pinchweld. Make sure there are no contaminants and do not touch the pinchweld after you have prepped the area.

31. Apply the pinchweld primer only to the areas where needed, and follow the urethane manufacturer's recommendations. Allow preps and primers to dry as recommended by the urethane manufacturer.

32. Apply a triangular bead of urethane to the same path as the freshly cut urethane on the pinchweld. Before cutting your V-notch, cut the tip off of your nozzle with a nozzle-cutter. With the cut nozzle, measure to the top of the roofline, and at 1/16-inch higher than the roofline, make a mark on the nozzle with a pen or marker. Notch the nozzle up to the marked line; this will give you the appropriate triangular bead.

33. Lift the windshield from the windshield stand or workstation using vacuum cups. Set the windshield on the urethane at the mark you made during your dry fit. Lower the driver's side of the windshield onto the urethane and line it up with the dry-fit mark; it is now in place.

34. The windshield is now ready to be decked. Press firmly to ensure a good seal.

35. Before re-installing the parts, check for leaks. Use a leak detector to go over the perimeter of the windshield. If you find a leak, apply more pressure or add more urethane to the spot and ensure that the glass makes contact with the wet urethane.

36. Re-install the removed parts in reverse order.

37. Check operation of the rain sensor by sprinkling the lens window with water and observing the wiper movement. It should clear the window of moisture and stop.

38. Allow the urethane to cure according to the urethane manufacturer's recommended cure time before returning the vehicle to the customer. Warning: Disregarding the safe drive-away time that your urethane manufacturer recommends could jeopardize the structural integrity of the vehicle and the safety of its passengers.

39. You have completed the removal and replacement of the windshield. 

© 2011 National Glass Association. All rights reserved. Visit GlassMagazine.com for glass removal and replacement instructions for more than 450 vehicles. To sign up to receive the For Technicians Only e-bulletin, email FTO@glass.org.