Remove/install rear window

AR67.20-D-5145H

Remove/install rear window

23.02.2017

Model

900, 906

with code W61 (Window in tailgate / Rear hinged doors)

Modification notes

14.11.2016

Adhesive change. Use of preheater no longer required.

Operation step 1

AR67.10-D-1000-12H

28.11.2016

Since it no longer necessary to preheat the 1-component adhesive cartridge, the 1-component adhesive cartridge can be prepared later.

Operation step 12

Shown on left rear window (1)

1

Rear window

2

Spacers

3

Cover

 Warning

Injury hazard from pinching and crushing, in extreme cases extremities can even be cut off when caught in windshield wiper mechanism.

When working on the windshield wiper mechanism, always switch off the ignition and store transmitter key outside of transmission range (at least 2 m).

AS82.30-Z-0001-01A

Topical note

Notes on carrying out repair work in the vehicle interior

AH68.00-N-0001-01S



Remove

1

Check adjustment on left and right rear-end door, correct if required

AR72.20-D-1032E

2

Remove rear window wiper arm on left and right rear-end door

MODEL 906 with CODE W78 (Window in liftgate or hinged rear door with wiper and washer system)

3

Remove cover (3) from right rear-end door

When replacing right rear window (1).

4

Remove curtain rails with curtain from left and right rear-end door

MODEL 906.657 with CODE PE4 (Mastercode Bus DCAA, Argen) or with CODE PE5 (Mastercode Bus platform seating, Argen)

AR68.50-D-5601A

5

Remove school bus rear warning sticker

MODEL 906.657 with CODE PE4 (Mastercode Bus DCAA, Argen) or with CODE PE5 (Mastercode Bus platform seating, Argen)

AR86.00-D-1200A

6

Disconnect electrical connector on rear window heater from left and right rear window (1)

MODEL 906 with CODE H22 (Heated rear window)

7

Fasten two cup suction tools on rear window (1)

 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

8

Cut out rear window (1) and remove with cup suction tools

AR67.10-P-1000-11SX

9

Vacuum off glass splinters and contamination

Preparation

10

Prepare rear door window cutout for installation

AR67.20-D-5160-01A

 Ensure that not more than 1 mm of adhesive bead remains. Pull off loose adhesive material (remaining pieces which are not completely cut off). Repair paint damage not covered by glue with primer.
Use felt scraper.

Repair kit for installing windshields, 1-component adhesive

*BR00.45-Z-1180-02A

Glazing repair kit 500662 01/03/05/07/09/11

*BR00.45-Z-1031-02A

11

Prepare adhesive for rear window (1)

When using 2-component adhesive.

AR67.10-D-1000-07A

Glazing repair kit 500662 01/03/05/07/09/11

*BR00.45-Z-1031-02A

12

Prepare adhesive for rear window (1)

When using 1-component adhesive.

AR67.10-D-1000-12H

Repair kit for installing windshields, 1-component adhesive

*BR00.45-Z-1180-02A

 Adapter

*000589866300

13

Prepare rear window (1) for installation

AR67.20-D-5145-03A

Repair kit for installing windshields, 1-component adhesive

*BR00.45-Z-1180-02A

Glazing repair kit 500662 01/03/05/07/09/11

*BR00.45-Z-1031-02A

14

Install spacers on window cutout in rear-end door

 Install 3  spacers at bottom on window cutout to prevent lowering rear window (1). One  spacer on the outside is sufficient for correct side alignment.

 Spacer

*901589076300

15

Glue in spacer blocks (2) inside next to adhesive bead on rear-end door


Glue spacer blocks (2) into vertical ridge from top and bottom.
Otherwise the rear window (1) can tilt.


The spacer blocks (2) should have a height of 6 mm.
Ensure that rear window (1) is seated correctly.

16

Open sliding door or side window


Open sliding door or side window.
This prevents the rear window (1) from being pressed outwards by the air pressure when the rear-end door is closed.



Install

17

Install rear window (1)

AR67.20-D-5145-04A


Do not press on rear window (1) too firmly.
Otherwise the rear window (1) can be damaged.


Install rear window (1) with 1-component adhesive within 10 min.
Install rear window (1) with 2-component adhesive within 5 min.
Otherwise the adhesive force of the glue starts to decrease.

 Observe curing time:
1-component adhesive min. 2 h.
2-component adhesive min. 1 h.

Repair kit for installing windshields, 1-component adhesive

*BR00.45-Z-1180-02A

Glazing repair kit 500662 01/03/05/07/09/11

*BR00.45-Z-1031-02A

18

Completely empty adhesive cartridge before disposal

 Glue residues not required can be disposed of in the household refuse.

19

Remove spacers after curing time

 Spacer

*901589076300

20

Connect electrical connector to rear window heater

MODEL 906.6/7 with CODE H22 (Heated rear window)

21

Install rear school bus warning sign

MODEL 906.657 with CODE PE4 (Mastercode Bus DCAA, Argen) or with CODE PE5 (Mastercode Bus platform seating, Argen)

AR86.00-D-1200A

22

Remove curtain rails with curtain from left and right rear-end door

MODEL 906.657 with CODE PE4 (Mastercode Bus DCAA, Argen) or with CODE PE5 (Mastercode Bus platform seating, Argen)

AR68.50-D-5601A

23

Install rear window wiper arm

MODEL 906 with CODE W78 (Window in liftgate or hinged rear door with wiper and washer system)

 MODEL 906.6/7 with CODE W78 (Window in liftgate or hinged rear door with wiper and washer system)Left/right wiper arm bolt

*BA72.20-N-1014-01C

24

Install cover (3) on right rear-end door

When replacing right rear window (1).

25

Clean rear window (1)

 Tailgate

Number

Designation

Model 906.6/7

BA72.20-N-1014-01C

Left/right wiper arm bolt

Nm

12

Repair materials

Number

Designation

Order number

BR00.45-Z-1031-02A

Glazing repair kit 500662 01/03/05/07/09/11

A 973 670 00 93

BR00.45-Z-1180-02A

Repair kit for installing windshields, 1-component adhesive

A 000 670 01 00