Remove/install rear window

AR67.20-S-5145E

Remove/install rear window

07.01.2020

Model

447

with code W65 (Tailgate)

except code W64 (Separately opening rear window)

Model

448

Modification notes

01.12.2016

Repair reference for 1-component adhesive replaced, work procedure and contents updated

Operation steps 1 to 3

AR67.10-S-1000-07S

01.12.2016

Repair reference for 1-component adhesive replaced

Operation step 2

AR67.20-S-5145-02S

01.12.2016

Repair reference for 1-component adhesive replaced

Operation step 13

01.12.2016

Work procedure and contents updated

Operation steps 1 to 15

1

Rear window

2

Rear window wiper

Topical note

Notes on carrying out repair work in the vehicle interior

AH68.00-N-0001-01S

Topical note

Notes on removal/installation of windows

AH67.10-P-1000-02RT



Remove

1

Lower side window in front door

2

Remove rear window wiper (2)

Model 447, 448 with code W65 (Liftgate) model 448.8 with code W68 (Electrically actuated liftgate)

AR82.30-S-6980E

3

Remove inner paneling from window frame on liftgate

Model 447.7 with code VK7 (Rear door/liftgate, luxury version) with code ZU7 (National version Canada) Model 447.7 with code VK7 (Rear door/liftgate, luxury version) with code ZU8 (National version USA) Model 447.7, 448.7 with code V23 (Interior trim, luxury version) Model 447.8, 448.8

AR72.20-S-1015E

4

Remove liftgate paneling

AR72.20-S-6445E

5

Disconnect electrical connectors from rear window (1)

6

Remove liftgate wiper motor

AR82.30-S-6550E

 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

7

Cut out windshield (1) with window removal tool

AR67.10-P-1000-11SX

 Commercially available devices/tools
Window cutter
Cup suction tool/shackle (for removing and installing windows)

 Punch pipe probe for cutting wire at marked point (arrow) through adhesive seam.



Clean

8

Remove glue residues from body flange

 Cut residual adhesive down to approx. 1 mm and remove loose adhesive material.

9

Vacuum off glass splinters and contamination

 Commercially available devices/tools
Wet and dry vacuum cleaner

10

Remove remaining adhesive material on removed rear window (1)

If rear window (1) is not replaced.


A maximum of 1 mm residual adhesive may be left.
Otherwise the strength of the adhesive connection can be impaired and proper adhesion of the adhesive material is not ensured.

 Cut residual adhesive down to approx. 1 mm and remove loose adhesive material.



Install

11

Prepare adhesive cartridge

AR67.10-S-1000-07S

 Commercially available devices/tools
Electric and pneumatic cartridge gun

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

 Adapter

*000589866300

12

Attach new adhesive foil to rear window (1)

When replacing rear window (1).

Model 447.8
with code W65 (Tailgate)
with code ZK7 (Equipment line MARCO POLO)
except code W50 (Rear-end door, double-wing, 180 degrees without window)
except code W54 (2-wing rear-end door, 270 degrees)
except code W64 (Separately opening rear window)

AR67.20-S-5145-10E

13

Apply primer to ground surface on liftgate

Topical note

General notes about painting the body flange in the glazing area

AH98.00-P-9408-06A


Do not apply primer on top of residual adhesive.
Otherwise, the adhesive effect will be impaired.

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

*BR00.45-Z-1031-02A

Repair kit for installing windshields, 1-component adhesive

*BR00.45-Z-1180-02A

14

Replace rubber spacer disks and all spacers

AR67.30-S-4050-02E

 Rubber spacer disks and spacers are available from EPC.

15

Glue in rear window (1)

AR67.20-S-5145-02S


The object and room temperature should be min. 15 °C and should not exceed 35 °C.
Otherwise the strength of the adhesive connection can be impaired and proper adhesion of the adhesive material is not ensured.


Glue in rear window (1) within 5 min.
Otherwise the strength of the adhesive connection can be impaired and proper adhesion of the adhesive material is not ensured.


Do not move vehicle for at least 2 h after gluing in rear window (1).
Otherwise the strength of the adhesive connection can be impaired and proper adhesion of the adhesive material is not ensured.

 Commercially available devices/tools
Cup suction tool/shackle (for removing and installing windows)

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

*BR00.45-Z-1031-02A

Repair kit for installing windshields, 1-component adhesive

*BR00.45-Z-1180-02A

16

Align rear window (1) immediately after installing and fasten with suitable adhesive tape

AR67.20-S-4050-04E

 Observe gap dimension "HA".

Model 447
with code W65 (Tailgate)
except code W50 (Rear-end door, double-wing, 180 degrees without window)
except code W54 (2-wing rear-end door, 270 degrees)
except code W64 (Separately opening rear window)
Model 448
with code W65 (Tailgate)
Model 448
with code W68 (Electrically operated liftgate)Gap dimensions

*BE60.00-N-1008-01J

 Feeler gauge

*129589032100

17

Connect electrical connectors to rear window (1)

18

Install liftgate wiper motor

AR82.30-S-6550E

19

Install rear window wiper (2)

Model 447, 448 with code W65 (Liftgate) Model 448.8 with code W68 (Electrically actuated liftgate)

AR82.30-S-6980E

20

Install liftgate paneling

AR72.20-S-6445E

21

Install inner paneling on window frame of liftgate

Model 447.7 with code VK7 (Rear door/liftgate, luxury version) with code ZU7 (National version Canada) Model 447.7 with code VK7 (Rear door/liftgate, luxury version) with code ZU8 (National version USA) Model 447.7, 448.7 with code V23 (Interior trim, luxury version) Model 447.8, 448.8

AR72.20-S-1015E



Clean

22

After the adhesive material has cured, remove adhesive tape and clean rear window (1) and vehicle interior in repair area



Check

23

Check rear window heater proper function

Gap dimensions

Number

Designation

Model 447, 448 with code W64, W65, W68

BE60.00-N-1008-01J

Gap dimensions

Rear window in liftgate, all-round

Dimension "HA"

mm

4 (1)

Folding rear window in liftgate, all-round

Dimension "HB"

mm

4 (1)

Liftgate to taillamp

Dimension "HC"

mm

4,5 (1)

Liftgate to bumper at side

Dimension "HD"

mm

4 (1)

Liftgate to bumper at bottom

Dimension "HE"

mm

6 (1,5)

Liftgate to roof frame

Dimension "HF"

mm

5,5 (1)

For picture, see

AR60.00-S-0700-01E

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