Remove/install seal on crossmember above windshield

AR77.50-P-4050W

Remove/install seal on crossmember above windshield

12.3.12



Removing

1

Remove outer paneling on left and right A-pillar (3)

AR88.80-P-8500W

2

Remove expansion clip (2) from left and right A-pillar (3)

 Clip remover

*452589016300

3

Remove seal (1) from windshield crossmember (4) and A-pillars (3)



Clean

4

Remove sealant residues and clean sealing surfaces on windshield crossmember (4) and A-pillars (3)

The sealing surfaces must be free of oil and grease. Otherwise leakage is not possible

 Observe drying time for cleaning agent

It is not necessary to clean the seal (1) because it is always replaced after removal

Cleaner

*BR00.45-Z-1025-04A



Install

5

Lay Ø 4 mm sealing profiles (7) in center on windshield crossmember (4)

 Do not touch Ø 4 mm sealing profile (7) with bare fingers.
Length of Ø 4 mm sealing profile (7)

approx. 550 mm. The Ø 4 mm sealing profiles (7) should overlap clearly (arrow C) in the center of the windshield crossmember (4).

Sealing profile

*BR00.45-Z-1084-01A

6

Lay Ø 4 mm sealing profile (5) at both A-pillars (3) and windshield crossmember (4) starting at the upper end of the retaining rail (9)

 Do not touch Ø 4 mm sealing profile (5) with bare fingers.
Length of Ø 4 mm sealing profile (5)
approx. 700 mm.
The distance (A) to the retaining rail (9) should be approx. 8 mm. For this purpose take backing (12) of Ø 4 mm sealing profile (5) as reference.

Route Ø 4 mm sealing profile (5) below hole (arrow E).

Sealing profile

*BR00.45-Z-1084-01A

7

Lay Ø 6 mm sealing profile (6) at upper corner on left and right A-pillar (3)

 Ø 6 mm sealing profile (6) should overlap clearly with Ø 4 mm sealing profile (7) and Ø 4 mm sealing profile (5). Otherwise leakage can occur later

 Do not touch dia. 6 mm sealing profile (6) with bare fingers
Length of dia. 6 mm sealing profile (6)
approx. 50 mm.

Route Ø 6 mm sealing profile (6) below pin-in nuts (8).

Butyl cord

*BR00.45-Z-1085-01A

8

Position seal (1) on windshield crossmember (4) with both corner elements (arrows B), align corner elements (arrows B) on pull-in nuts (8) and press seal (1) to windshield crossmember (4) toward center.

 Use new seal (1)
Helper is required for positioning and aligning seal (1) Two holes are present on the corner brackets (arrows B) for the bolts for mounting the outer paneling to the A-pillar (3).
The corner elements (arrows B) are aligned to the pull-in nuts (8) with these holes
Ensure that the shaped parts (13) on the seal (1) are seated correctly in the left and right retaining rail (9).

9

Align seal (1) on left and right retaining rail (9) and position

 The seal (1) must be positioned on the cutout (arrow) on the left and right retaining rail (9) as shown.

10

Press seal (1) to A-pillars (3) and windshield crossmember (4) over entire length with roller (10)

 Carefully roll on seal (1). Otherwise, the seal can be damaged if pressed too firmly.

 Press seal (1) down in routing area of sealing cords (5, 6, 7).

 Roller

*171589066300

11

Cut ends of Ø 4 mm sealing profile (5) extending beyond both A-pillars (3) flush with seal (1) using a clip remover and remove

 Clip remover

*452589016300

12

Press seal (1) on with  roller (11) in crosshatched areas.

 Roller

*168589056300

13

Install expansion clips (2)

14

Install paneling on left and right outer A-pillar (3)

AR88.80-P-8500W

15

Clean seal (1) and adjacent body parts

 While cleaning check whether seal (1) is seated correctly

Cleaner

*BR00.45-Z-1025-04A



Checking

16

Visual check

 Check contact on roof frame.

17

Perform rain test

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