Remove/install rear passenger compartment side window

AR67.30-S-2701E

Remove/install rear passenger compartment side window

12.09.2018

Model

447.8

with code W05 (Rear windows, left side fixed, right side hinged)

Model

447

with code W29 (Window fixed behind)

Model

448.7

with code W29 (Window fixed behind)

Model

448.8

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

AR67.30-S-2700-03S

01.12.2016

Repair agent reference 1-component adhesive replaced

Operation step 15

01.12.2016

Work procedure and contents updated

Operation steps 1 to 18

Shown on model 447.8 with code VQ1 (AVANTGARDE) and code W29 (Stationary rear window) on right side of vehicle

1

Side window(s)

2

Trim piece

3

Cup suction tool

Model 447.8 with code ZK7 (MARCO POLO equipment line)

1

Side window(s)

4

Cover

5

Frame seal

6

Roller sun blind

 Warning

Risk of injury caused by fingers being jammed or pinched when removing, installing or aligning hoods, doors, trunk lid/rear-end door or sliding roof.

No parts of the body or limbs should be within the operating area when the components are moving.

AS00.00-Z-0011-01A

Topical note

Notes on removal/installation of windows

AH67.10-P-1000-02RT

Topical note

Notes on carrying out repair work in the vehicle interior

AH68.00-N-0001-01S



Remove

1

Lower side window in front door

2

Remove trim piece (2) from sidewall paneling

Model 447.8 with code VQ1 (AVANTGARDE) Model 447.8 with code VQ8 (EXCLUSIVE equipment line) Model 448.8

AR88.85-S-9846E

3

Install cup suction tool (3) on outer side window (1)

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

4

Remove roller sun blind (6)

Model 447.8
with code W05 (Rear windows, left side fixed, right side hinged)
with code ZK7 (Equipment line MARCO POLO)

AR68.50-S-0004E

5

Remove cover (4)

Model 447.8
with code W05 (Rear windows, left side fixed, right side hinged)
with code ZK7 (Equipment line MARCO POLO)

AR68.30-S-4490E

6

Detach sealing frame (5), cut and remove

Model 447.8
with code W05 (Rear windows, left side fixed, right side hinged)
with code ZK7 (Equipment line MARCO POLO)

 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

7.1

Cut out side window (1) with cutting wire

Model 447.8
with code W05 (Rear windows, left side fixed, right side hinged)
with code ZK7 (Equipment line MARCO POLO)

AR67.30-S-4050-03E


Protect working area against damage from cutting wire with suitable material.
Damage may occur otherwise.

 Commercially available devices/tools
Cutting wire with handles

 Punch pipe probe for cutting wire through adhesive seam at front top on side window (1) (arrow).
Have second person help.

 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

7.2

Cut out side window (1) with window removal tool

Model 447
with code W29 (Window fixed behind)
Model 448.7
with code W29 (Window fixed behind)
Model 448.8

AR67.10-P-1000-11SX

 Commercially available devices/tools
Window cutter

 Punch pipe probe for cutting wire through adhesive seam at front top on side window (1) (arrow).
Have second person help.

8

Remove cup suction tool (3) from side window (1)

If side window (1) is replaced.



Clean

9

Remove glue residues from body flange

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

10

Vacuum off glass splinters and contamination

 Commercially available devices/tools
Wet and dry vacuum cleaner



Install

11

Install cup suction tool (3) on outer side window (1)

If side window (1) is replaced.

12

Attach adhesive foil on side window (1)

If left rear side window (1) is replaced.

Model 447.8
with code W05 (Rear windows, left side fixed, right side hinged)
with code ZK7 (Equipment line MARCO POLO)

AR67.30-S-2700-01E

13

Install new bracket for trim piece (2) on side window (1)

If side window (1) is replaced.

Model 447.8## ## as of 106314 with code VQ1 (AVANTGARDE) Model 447.8## ## as of 106314 with code VQ8 (EXCLUSIVE equipment line) Model 448.8

AR88.85-S-9846-01EE



Fastening for trim piece modified

Model 447.8
with code VQ1 (AVANTGARDE)
with code W29 (Window fixed behind)

BT88.85-S-9845-01E

 MODEL 447.8## ## up to 106313
Method for model 447.8## ## as of 106314 is to be used for mounting the trim piece (2).

14

Install sealing frame (5)

Model 447.8
with code W05 (Rear windows, left side fixed, right side hinged)
with code ZK7 (Equipment line MARCO POLO)

15

Apply primer to primed surface on body flange

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

16

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

17

Replace all spacers

AR67.30-S-4050-02E

 Spacers are available from EPC.

18

Glue in side window (1)

AR67.30-S-2700-03S


Glue in side window (1) within 5 min.
Otherwise the adhesive effect may be impaired.

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

 Use aid of helper.

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

19

Align side window (1) in body opening and fasten with suitable adhesive tape

AR67.30-S-4050-04E


Align side window (1) immediately after installation.
Otherwise the adhesive effect may be impaired.

 Observe gap dimension "GF".

Gap dimensions

*BE60.00-N-1007-01J

 Feeler gauge

*129589032100

20

Remove cup suction tool (3)

 Remove cup suction tool (3) only after end of curing time.
Observe the drying time specified by the adhesive manufacturer.

21

Remove trim piece (2) from sidewall paneling

Model 447.8 with code VQ1 (AVANTGARDE) Model 447.8 with code VQ8 (EXCLUSIVE equipment line) Model 448.8

AR88.85-S-9846E

22

Install panel (4)

Model 447.8
with code W05 (Rear windows, left side fixed, right side hinged)
with code ZK7 (Equipment line MARCO POLO)

AR68.30-S-4490E

23

Install roller sun blind (6)

Model 447.8
with code W05 (Rear windows, left side fixed, right side hinged)
with code ZK7 (Equipment line MARCO POLO)

AR68.50-S-0004E



Clean

24

Remove adhesive strips and clean side window (1) as well as vehicle interior

 Observe the curing time of the adhesive.

Gap dimensions

Number

Designation

Model 447, 448 except code W65, W68

Model 447, 448 with code W65, model 447, 448 with code W68

BE60.00-N-1007-01J

Gap dimensions

Sidewall to liftgate

Dimension "GA"

mm

-

4,5 (+1,5/-0,2)

Sidewall to cover on guide rail of sliding door

Dimension "GB"

mm

1,5 (0,8)

1,5 (0,8)

Sidewall to fuel filler door

Dimension "GC"

mm

4,5 (1)

4,5 (1)

Glass pane in sidewall at front, all-round

Dimension "GD"

mm

3

3

Sidewall to taillamp

Dimension "GE"

mm

1,2 (0,5)

1,2 (0,5)

Glass pane in sidewall at rear, all-round

Dimension "GF"

mm

3

3

For picture, see

AR60.00-S-0700-01E

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