Completely remove/install sliding window

AR67.30-S-5311E

Completely remove/install sliding window

21.12.2016

Model

447.7/8

with code W18 (Sliding window front left in sidew./sliding door)

Model

447.7/8

with code W19 (Sliding window front right in sidew./sliding door)

Modification notes

01.12.2016

Work procedure and contents updated

Operation steps 1 to 28

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

AR67.30-S-2700-03S

Shown with CODE W18 (Left front sliding window in side wall/sliding door)

1

Sliding window

2

Lower window guide rail

3

Seal

4

Screw

6

Cover

5

Screw

7

Clips

 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



Notes on removal/installation of windows

AH67.10-P-1000-02RT



Notes on carrying out repair work in the vehicle interior

AH68.00-N-0001-01S



Remove

1

Lower side window in one front door

2

Remove paneling from kitchenette and lay down to side

Model 447.8
with code W18 (Sliding window front left in sidew./sliding door)
with code ZK7 (Equipment line MARCO POLO)

AR86.60-S-0002E

 Do not disconnect electrical connectors.
Place paneling of kitchenette down to side with electrical lines connected.

3

Remove trim from C-pillar

Model 447.8
with code W18 (Sliding window front left in sidew./sliding door)
with code ZK7 (Equipment line MARCO POLO)

AR68.30-S-4490E

4

Remove bolts (4, 5)

Model 447.8
with code W18 (Sliding window front left in sidew./sliding door)
with code ZK7 (Equipment line MARCO POLO)

5

Remove paneling (6) from clips (7)

Model 447.8
with code W18 (Sliding window front left in sidew./sliding door)
with code ZK7 (Equipment line MARCO POLO)

 For this purpose lift paneling (6) and pull to vehicle interior in direction of arrow.

6

Remove sealing (3)

 Observe assembly positon of seal (3).
Seal (3) must be replaced.

7

Install two cup suction tools on outside of sliding window (1)

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

8

Cover lower window guide rail (2) with suitable adhesive tape

When the sliding roof (1) is not replaced.

 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

9

Cut out side window (1) with window removal tool

AR67.10-P-1000-11SX

 Commercially available devices/tools
Window cutter

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

 The sliding window (1) can only be cut out as complete unit. If the sliding element of the sliding window (1) is defective or damaged, replace sliding window (1).

10

Remove cup suction tool



Clean

11

Remove glue residues from body flange

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

12

Remove adhesive residues from removed sliding window (1)

When the sliding roof (1) is not replaced.

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

13

Clean bonding surface on seal (3) of sliding window (1)



Check

14

Check clips (7) for damage

Model 447.8
with code W18 (Sliding window front left in sidew./sliding door)
with code ZK7 (Equipment line MARCO POLO)

Depending on findings



Replace clamps (7).



Install

15

Install panel (6)

Model 447.8
with code W18 (Sliding window front left in sidew./sliding door)
with code ZK7 (Equipment line MARCO POLO)

 It is no longer possible to install the paneling (6) with installed sliding window (1).

16

Screw in screws/bolts (4, 5)

Model 447.8
with code W18 (Sliding window front left in sidew./sliding door)
with code ZK7 (Equipment line MARCO POLO)

17

Install two cup suction tools on outside of new sliding window (1)

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

18

Apply primer to primed surface on body flange



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

19

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

20

Glue on new seal (3) approx. 1 mm below top edge of sliding window (1)

 Observe assembly position.

21

Replace all spacers

 Spacers are available from EPC.
Observe assembly position of removed spacers.

22

Glue in sliding window (1)

AR67.30-S-2700-03S


Glue in sliding 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)

 Have second person help.

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

23

Align sliding window (1) in body shell aperture immediately after installing and fix in place with suitable adhesive tape

AR67.30-S-4050-04E

 Observe gap dimensions "GD" and "FC".

Model 447.7/8 except code W65 (Liftgate) except code W68 (Electrically actuated liftgate) Model 447.7/8 with code W65 (Liftgate) Model 447.7/8 with code W68 (Electrically actuated liftgate)Gap dimensions

*BE60.00-N-1006-01J

Model 447.7/8 except code W65 (Liftgate) except code W68 (Electrically actuated liftgate) Model 447.7/8 with code W65 (Liftgate) Model 447.7/8 with code W68 (Electrically actuated liftgate)Gap dimensions

*BE60.00-N-1007-01J

 Feeler gauge

*129589032100

24

Remove cup suction tool

25

Install molding onto C-pillar

Model 447.8
with code W18 (Sliding window front left in sidew./sliding door)
with code ZK7 (Equipment line MARCO POLO)

AR68.30-S-4490E

26

Install paneling on front kitchenette

Model 447.8
with code W18 (Sliding window front left in sidew./sliding door)
with code ZK7 (Equipment line MARCO POLO)

AR86.60-S-0002E



Check

27

Check sliding element of sliding window (1) for proper function

 Check sliding window (1) after end of curing time for proper function.



Clean

28

Clean sliding window (1) and vehicle interior

 Clean sliding window (1) only after end of curing time.
The drive-away time for the 2-component repair kit is 1 h.

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-1006-01J

Gap dimensions

Sliding door to roof frame

Dimension "FA"

mm

4,5 (1,4)

4,5 (1,4)

Sliding door to sidewall

Dimension "FB"

mm

4 (+1,2/-0,8)

4 (+1,2/-0,8)

Glass pane in sliding door, all-round

Dimension "FC"

mm

3

3

For picture, see

AR60.00-S-0700-01E

AR60.00-S-0700-01E

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