Remove/install rear window

AR67.20-S-5145C

Remove/install rear window

19.12.2016

Model

415

with code W50 (Rear-end door, double-wing, 180 degrees without window)

with code W78 (Window in tailgate or hinged rear door with wipe/wash system)

Model

415

with code W65 (Tailgate)

with code W78 (Window in tailgate or hinged rear door with wipe/wash system)

Modification notes

01.12.2016

Repair agent reference 1-component adhesive replaced, wok procedure and contents updated

Operation steps 1 to 3

AR67.10-S-1000-07S

01.12.2016

Repair agent reference 1-component adhesive replaced

Operation step 2

AR67.20-S-5145-02C

01.12.2016

Repair agent reference 1-component adhesive replaced

Step 6

01.12.2016

Work procedure and contents updated

Operation steps 1 to 12

Shown with CODE W50 (Rear-end door, two-wing, 180 degrees without window)

1

Rear windows

Shown with code W65 (Liftgate)

1

Rear window



Notes on removal/installation of windows

AH67.10-P-1000-02RT



Remove

1.1

Remove rear window wiper

Model 415
with code W50 (Rear-end door, double-wing, 180 degrees without window)
with code W78 (Window in tailgate or hinged rear door with wipe/wash system)
Only when replacing rear window (1) in left rear door.

AR82.30-S-6980C

1.2

Remove liftgate wiper motor

Model 415
with code W65 (Tailgate)
with code W78 (Window in tailgate or hinged rear door with wipe/wash system)
Only when removing rear window (1) on liftgate.

AR82.30-S-6550C

2

Remove cargo area cover

MODEL 415 with CODE V57 (Luggage compartment cover)

3

Disconnect electrical connectors from rear window heater

Only when replacing rear window (1) in left rear door or liftgate.

 Danger !

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

4

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 through adhesive seam at easily accessible point.



Clean

5

Remove glue residues from body flange

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



Install

6

Prepare body flange for installation of window



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.

 Apply primer to body flange only on primed surface.

Repair kit for installing windshields, 1-component adhesive

*BR00.45-Z-1180-02A

7

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

 Adapter

*000589866300

8

Glue in rear window (1)

AR67.20-S-5145-02C


Install rear window (1) within 5 min.
Ensures that the adhesive force is not decreased.

 Observe gaps.

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

Repair kit for installing windshields, 1-component adhesive

*BR00.45-Z-1180-02A

Model 415 with code W65 (Liftgate)Check gap dimensions

*BE60.00-N-1006-01D

Model 415 with code W50 (Rear-end door, two-wing, 180 degrees without window)Check gap dimensions

*BE60.00-N-1007-01D

 Feeler gauge

*129589032100

9

Connect electrical connectors for rear window heater

Only when installing rear window (1) in left rear-end door or liftgate.

10

Install luggage compartment cover

MODEL 415 with CODE V57 (Luggage compartment cover)

11.1

Install rear window wiper

Model 415
with code W50 (Rear-end door, double-wing, 180 degrees without window)
with code W78 (Window in tailgate or hinged rear door with wipe/wash system)
Only when installing rear window (1) in left rear-end door.

AR82.30-S-6980C

11.2

Install liftgate wiper motor

Model 415
with code W65 (Tailgate)
with code W78 (Window in tailgate or hinged rear door with wipe/wash system)
Only when installing rear window (1) on liftgate.

AR82.30-S-6550C



Clean

12

Clean rear window (1)

 Clean window (1) only after end of curing time.

Test and adjustment values for gap dimensions

Number

Designation

Model 415.601

Model 415.603/605/703/705

BE60.00-N-1006-01D

Check gap dimensions

Liftgate to roof paneling

Dimension "U"

mm

10 (3)

10 (3)

Liftgate to rear window

Dimension "V"

mm

4 (1,5)

4 (1,5)

Liftgate to taillamp

Dimension "W"

mm

4 (2)

4 (2)

Liftgate to rear bumper at bottom

Dimension "X"

mm

7,2 (3)

7,2 (3)

Liftgate to rear bumper at side

Dimension "Y"

mm

4 (2)

4 (2)

For picture, see

AR60.00-S-0700-01C

AR60.00-S-0700-01C

Test and adjustment values for gap dimensions

Number

Designation

Model 415.601

Model 415.603/605/703/705

BE60.00-N-1007-01D

Check gap dimensions

Bumper at rear to taillamp

Dimension "Z"

mm

2 (1,5)

2 (1,5)

Left rear-end door to right rear-end door

Dimension "AA"

mm

4 (2)

4 (2)

Rear-end door to roof paneling

Dimension "AB"

mm

10 (3)

10 (3)

Rear-end door to taillamp

Dimension "AC"

mm

4 (2)

4 (2)

Rear-end door to bumper at side rear

Dimension "AD"

mm

4 (2)

4 (2)

Rear-end door to bumper at bottom rear

Dimension "AE"

mm

7,2 (3)

7,2 (3)

Rear-end door to rear window

Dimension "AF"

mm

4 (1,5)

4 (1,5)

Side edge of left rear window to side edge of right rear window

Dimension "AG"

mm

4 (2)

4 (2)

For picture, see

AR60.00-S-0700-01C

AR60.00-S-0700-01C

Repair materials

Number

Designation

Order number

BR00.45-Z-1180-02A

Repair kit for installing windshields, 1-component adhesive

A 000 670 01 00