Remove/install rear wall window

AR67.20-P-2000GQS

Remove/install rear wall window

23.02.2017

Model

166

with code Z04 (Light armoring)

1

Heated rear window electrical connector

2

Heated rear window ground point

3

AM/FM amplifier electrical connector

4

Amplifier electrical connector

A2/18

FM 1, AM, CL [ZV] and KEYLESS GO antenna amplifier

A2/19

FM 2, DAB and TV antenna amplifier

Shown on model 164

A

Adhesive strips

8

rear-end door window

9

Aramid cord

 Warning

Risk of injury from cutting wire tearing or becoming hot and from splinters of glass when cutting out bonded windows

Wear protective gloves and safety glasses.

AS67.00-Z-0004-01A

 Caution

Risk of injury from pinching or crushing hands and feet when working on windows.

Secure the windshields and windows against falling down; use only specified lifting tools; wear safety shoes.

AS67.00-Z-0003-01A

 Caution

Risk of injury caused by scraping or cutting body parts on sharp vehicle parts

Always wear protective gloves when working on or near sharp and non-deburred vehicle parts.
Deburr repair panels.

AS00.00-Z-0017-01A



Remove

1

Determine distance between bottom edge of rear-end door window (8) and edge of rear-end door paneling and note

 These dimensions are required for installation.

 Feeler gauge

*129589032100

2

Prepare 1-component adhesive cartridge

AR67.10-P-1000-12SX

Repair kit for installing windshields, 1-component adhesive

*BR00.45-Z-1135-02A

 Adapter

*000589866300

3.1

Switch off ignition and remove transmitter key from EIS control unit

Model 166
with code Z04 (Light armoring)
except code 889 (KEYLESS-GO)

3.2

Remove KEYLESS-GO start/stop button

Model 166
with code 889 (KEYLESS-GO)
with code Z04 (Light armoring)

 Press again until ignition is switched off.t. Remove the transmitter key from the vehicle and store it in a location beyond its transmission range (at least 2 m).

4

Remove rear spoiler

AR72.20-P-4000GQ

5

Remove rear-end door wiper motor

AR82.30-P-6900GZ

6

Disconnect electrical connector for heated rear window (1) and heated rear window (2) ground point and fasten to rear-end door window (8) with adhesive tape

Notes on avoiding damage to windows installed in special high-security vehicles

AH67.00-P-0003-01FB


Ensure that adhesive tape is not bonded directly to inside of rear-end door window (8); previously cover window with suitable foil.
Because the rear-end door window (8) has a sensitive plastic coating on the inside.

7

Attach protective foil

When reusing rear window.

8

Disconnect electrical connector from FM/AM amplifier (3) and electrical connector for amplifier (4) from FM 2, DAB and TV antenna amplifier (A2/19) and fasten to rear window with adhesive tape

Notes on avoiding damage to windows installed in special high-security vehicles

AH67.00-P-0003-01FB


Ensure that adhesive tape is not bonded directly to inside of rear-end door window (8); previously cover window with suitable foil.
Because the rear-end door window (8) has a sensitive plastic coating on the inside.

9

Secure rear-end door window (8) with textile adhesive tape against falling down when cutting out

10

Expose aramid cord (9) at top right with rear spoiler removed

11

Pull aramid cord marked in yellow around unmarked aramid cord toward left in direction of travel; then pull unmarked aramid cord to right below other aramid cord

 Removal: Any other procedure can result in the aramid cords crossing and tearing during removal. Helper required to secure second end of cord before pulling in.
Mask areas around rear-end door window (8).



Install

12

Prepare body flange for installation of rear window

AR67.20-P-2000-09GZ

Topical note

General notes about painting the body flange in the glazing area

AH98.00-P-9408-06A

Repair kit for installing windshields, 1-component adhesive

*BR00.45-Z-1135-02A

Primer stick

*BR00.45-Z-1012-07A

Hepox 2K EP primer filler 4017 (Spray Max)

*BR00.45-Z-1050-07A

13

Replace window rubber spacers on rear-end door

AR67.20-P-3550-02GZ

14

Attach protective foil

15

Fasten electrical connectors (1, 3, 4) to rear-end door window (8)


Ensure that adhesive tape is not bonded directly to inside of rear-end door window (8); previously cover window with suitable foil.
Because the rear-end door window (8) has a sensitive plastic coating on the inside.

16

Align rear-end door window (8) in body opening

If old rear-end door window (8) is no longer present on rear-end door.

 Position rear-end window (8) in body opening with aid of helper and center so that the distance between the rear-end door window (8) and the edge of the rear-end door paneling can be determined and noted. Attach adhesive strips (A) as centering aid, cut along outer edge of window and remove rear-end door window (8).

17

Open driver door side window


The side window in the driver door must be open during the curing time of the adhesive material.
This prevents the rear-end door window (8) from being pressed outwards by the air pressure when a door is closed.

18

Prepare rear-end door window (8) for installation

AR67.20-P-1000-07GZ

19

Route aramid cord (9) so that it overlaps


Do not attach aramid cord (9) at window radiuses.
Otherwise the aramid cord (9) can tear at these points the next time the window is removed. Overlap aramid cord at ends and fasten to outside of rear-end door window (8) with adhesive tape.

 When reusing rear-end door window (8) use new aramid cord.

20

Fasten aramid cord (9) at rear-end door window (8) at straight points with adhesive and allow adhesive to dry

21

Mark aramid cord routed toward left in direction of travel after installation with yellow touch-up paint pen and first guide around edge of window

 Any other procedure can result in the aramid cords crossing and tearing during removal.

22

Fasten aramid cord at outside of window with adhesive tape

 Any other procedure can result in the aramid cords crossing and tearing during removal.

23

Guide aramid cord routed toward right to aramid cord routed to left around edge of window and also fasten outside

 Any other procedure can result in the aramid cords crossing and tearing during removal.

24

Remove protection foil from rubber window spacers

25

Apply adhesive material to rear-end door window (8)

AR67.20-P-2000-08GZ


Install rear-end door window (8) within 10 minutes after applying adhesive material to rear-end door flange.
Otherwise the adhesive force of the glue starts to decrease.

 Adapter

*000589866300

26

Install rear-end door window (8)

 Installation:
Before laying rear-end window (8) down on adhesive, have a helper guide the electrical lines for the rear window heater and the antenna from the vehicle interior into the rear-end door. While holding the window approx. 10 cm in front of the adhesive.
Because this is no longer possible when the rear-end door window (8) is installed.

 Two helpers required. When aligning, observe noted dimensions between bottom edge of rear-end door window (8) to edge of rear-end door paneling.

27

Remove rear-end door gas-filled strut

AR72.20-P-3600GZ


After removing the rear-end door gas-operated strut, position rear-end door with telescopic lifter horizontally and put sufficient load on window.
So that the rear-end door window (8) is pressed correctly into the adhesive.

 After installing the rear-end door window (8) the vehicle should not be moved before the adhesive has dried (comply with manufacturer's specifications).

28

Install rear-end door gas-filled strut after drying

AR72.20-P-3600GZ

 After the window is installed and the adhesive dried, fasten both ends of aramid cord to vehicle with suitable adhesive tape.

29

Connect electrical connector for FM/AM antenna (3) to FM 2, DAB and TV antenna (A2/19) and electrical connector for amplifier (4) to FM 1, AM, ZV and KEYLESS-GO antenna amplifier (A2/18)

30

Connect electrical connector for heated rear window (1) and heated rear window ground point (2) and tighten

31

Install rear-end door wiper motor

AR82.30-P-6900GZ

32

Install rear spoiler

AR72.20-P-4000GQ

 Loosen ends of aramid cord (9) from outside of rear-end door window (8) and glue to rear-end door.

33

Check rear-end door window (8) for leakage

34

Clean window (8), adjacent painted paint parts and vehicle interior

Notes on avoiding damage to windows installed in special high-security vehicles

AH67.00-P-0003-01FB

35

Check all electrical consumers in area repaired for proper function

Repair materials

Number

Designation

Order number

BR00.45-Z-1012-07A

Primer stick

A 000 986 27 50

BR00.45-Z-1050-07A

Hepox 2K EP primer filler 4017 (Spray Max)

Spies Hecker Gmbh
Fritz-Hecker-Str. 47-107
50968 Cologne
Germany
Tel.: +49 221 370606
Fax. +49 221 3706410
www.spieshecker.com

BR00.45-Z-1135-02A

Repair kit for installing windshields, 1-component adhesive

A 221 670 81 01