Remove/install seal on crossmember above windshield

AR77.50-P-4050R

Remove/install seal on crossmember above windshield

19.7.11



Removing

1

Remove paneling left and right A-pillar (2)

AR88.80-P-8500R

2

Remove expansion clips (3) from A-pillars (2)

3

Remove windshield frame seal (1) from A-pillars (2) and pull out of retaining rails (4)

4

Remove windshield frame seal (1) from windshield crossmember (5)

5

Remove sealant residues from windshield crossmember (5) and clean sealing surfaces

 The sealing surfaces must be absolutely dry, free of dust and grease to prevent leaks.

 Observe drying time for cleaning agent

Cleaner

*BR00.45-Z-1025-04A

6

Remove sealant residues from windshield frame seal (1) and clean sealing surfaces

When reusing windshield frame seal (1).

 The sealing surfaces must be absolutely dry, free of dust and grease to prevent leaks.

 Observe drying time for cleaning agent

Cleaner

*BR00.45-Z-1025-04A



Install

7

Route butyl cord (6) from center of windshield crossmember (5) to outer upper corners (arrows A) of both retaining rails (4) as illustrated

 Do not touch butyl cord (6) with bare fingers to prevent leaks.

Sealing cord

*BR00.45-Z-1084-01A

8

Install butyl cords (7, 8) on both A-pillars (2) as illustrated

 Ensure that the present butyl cords on the A-pillar seals (2) and butyl cord (6) are connected correctly. Do not touch butyl cords (6, 7, 8) with bare fingers. Interruptions and soiling can lead to leaks.

Sealing cord

*BR00.45-Z-1084-01A

9

Install butyl cord (9) along marker line (arrow B) on windshield frame seal (1)

 Do not touch butyl cord (9) with bare fingers to prevent leaks.

 Ensure that newest version of windshield frame seal (1) is installed.
Observe installation position of butyl cord (9). Allow upper end of butyl cord (9) (arrow C) to taper out over a distance of approx. 5 to 10 mm.
Length of butyl cord (9) approx. 100 mm.

Butyl cord Terostat 81 Ø 6 mm

*BR00.45-Z-1085-01A

10

Install windshield frame seal (1) at upper end of both retaining rails (4)

 Ensure that windshield frame seal (1) is seated correctly at both retaining rails (4) because this operation serves for centering the windshield frame seal (1).

11

Apply lubricant to windshield frame seal (1) and press windshield frame seal (1) into both retaining rails (4) with assembly wedge. Then determine by visual inspection whether the windshield frame seal (1) completely arrests in retaining rails (4); if necessary, correct seat of windshield frame seal (1)

 Keep lubricant away from cleaned surfaces and butyl cords (6, 7, 8, 9) to prevent leaks.
The assembly wedges should not have any sharp edges to prevent damaging the windshield frame seal (1).



*110589035900

Antifriction agent

*BR00.45-Z-1010-06A

12

Firmly roll on windshield frame seal (1) first from outside to left lock mount (10), then from center of windshield crossmember (5) to left lock mount (10). Repeat this procedure on right side of vehicle

 Check whether butyl cord (6) is connected correctly to windshield frame seal (1); if necessary, roll on windshield frame seal (1) again.



*171589066300

13

Firmly press on windshield frame seal (1) in area of butyl cords (7, 8, 9)

14

Check whether butyl cords (6, 7, 8, 9) are connected directly to windshield frame seal (1); if necessary, press on windshield frame seal (1) again

15

Install new expansion clips (3)

16

Cut off any extending butyl cord (9)

 Do not tear off extending butyl cord (9) to prevent leaks.

17

Install paneling on left and right A-pillar (2)

AR88.80-P-8500R

18

Perform rain test in repair area

Number

Designation

Order number

BR00.45-Z-1084-01A

Rear window sealing profile

A 004 989 60 20

BR00.45-Z-1085-01A

Butyl cord Terostat 81 Ø 6 mm

A 004 989 61 20

BR00.45-Z-1025-04A

Cleaner

A 005 989 19 71

BR00.45-Z-1010-06A

Lubricant, rubber assembly 1 l

A 000 989 03 67