Remove/install windshield

AR67.10-P-1000EG

Remove/install windshield

23.02.2017

Model

212

with code Z04 (Light armoring)

1

Windshield

4

Drip molding

 Caution

Risk of injury caused by scraping or cutting body parts on sharp vehicle parts

Always wear protective gloves when working on or near sharp and non-deburred vehicle parts.
Deburr repair panels.

AS00.00-Z-0017-01A

 Caution

Risk of injury from pinching or crushing hands and feet when working on windows.

Secure the windshields and windows against falling down; use only specified lifting tools; wear safety shoes.

AS67.00-Z-0003-01A

 Warning

Risk of injury caused by slipping when inserting blade in the multicutter and byglass splinters when cutting out bonded windows

Always interrupt air supply or power supply before inserting or removing blade.
Wear protective gloves and safety glasses

AS67.00-Z-0001-01A

Topical note

Notes on avoiding damage to windows installed in special high-security vehicles

AH67.00-P-0003-01FB

Topical note

Information on preventing damage to electronic components due to electrostatic discharge

AH54.00-P-0001-01A



Remove

1

Cover dashboard, center console and front seats with suitable protective foil

2

Remove left and right A-pillar paneling

3

Remove left and right sun visor

4

Unclip cover from splinter protection plate

5

Loosen inside rear-view mirror and allow electrical lines to hang down

AR68.40-P-0001SX

6

Remove splinter protection plate

7

Remove multifunction camera

Model 212
with code 476 (Lane keeping assist)
with code Z04 (Light armoring)
Model 212
with code 513 (Speed Limit Assist)
with code Z04 (Light armoring)
Model 212
with code 608 (Adaptive Highbeam Assist)
with code Z04 (Light armoring)

AR54.21-P-3000EW

8

Remove infrared camera

Model 212
with code 610 (Night view assist)
with code Z04 (Light armoring)

AR54.30-P-3000SX

9

Remove rain/light sensor

AR82.30-P-7800CW

10

Remove wiper arms

AR82.30-P-6100CW

11

Remove air-water duct

12

Unclip left and right drip rail (4) from rear toward front and remove

 Long wedge

*115589035900

13

Disconnect electrical connector for heated windshield and fasten adhesive tape to windshield (1)

Model 212
with code Z04 (Light armoring)
with code Z17 (Heated windscreen)

14

Remove right front door sill molding

Model 212
with code Z04 (Light armoring)
with code Z17 (Heated windscreen)

AR68.30-P-4100EW

15

Loosen edge guard in area of lower right A-pillar paneling

Model 212
with code Z04 (Light armoring)
with code Z17 (Heated windscreen)

16

Remove right lower A-pillar paneling

Model 212
with code Z04 (Light armoring)
with code Z17 (Heated windscreen)

17

Loosen floor covering on front passenger footwell until electrical connectors are accessible

Model 212
with code Z04 (Light armoring)
with code Z17 (Heated windscreen)

18

Disconnect electrical connectors for windshield and remove contacts from connector

Model 212
with code Z04 (Light armoring)
with code Z17 (Heated windscreen)

AR00.19-P-0120-13A

 New passenger car wiring harness repair kit

*220589049900

 Wiring harness repair kit, basic

*000589139900

 Blade holder with clamping pliers

*220589019950

 LSK 8_blade

*220589019956

19

Fasten cord to both cable ends and expose wiring harness

Model 212
with code Z04 (Light armoring)
with code Z17 (Heated windscreen)

 To route wiring harness when installing.

20

Mask both A-pillars and roof front edge in connection area with adhesive tape

21

Cover area of air/water duct with suitable protective foil

22

Cut out windshield (1) and lift from body flange with crane and suction lifting device

AR67.10-P-1000-01TS


Helper required to guide windshield (1).
Otherwise adjacent body parts can be damaged.

 Use window removal tool FSC 1.6. Cutting plate, Z-shape, cutting length 60 mm order no. 6 39 03 081 01 3, www.fein.com

23

Prepare body flange for installation of window

AR67.10-P-1501-01P

Topical note

General notes about painting the body flange in the glazing area

AH98.00-P-9408-06A


The bonding areas on the body flange must be free of dust and grease.
Otherwise adhesion problems can occur when installing.

Repair kit for installing windshields, 1-component adhesive

*BR00.45-Z-1135-02A

Primer stick

*BR00.45-Z-1012-07A

24

Remove adhesive tape on A-pillars and front edge of roof



Install

25

Prepare adhesive cartridge

AR67.10-P-1000-12SX

Adhesive parts kit (with heptane cleaner)

*BR00.45-Z-1142-02A

Repair kit for installing windshields, 1-component adhesive

*BR00.45-Z-1135-02A

 Adapter

*000589866300

26

Replace rubber window spacer

 Do not remove backing foil.

27

Glue new seal to windshield (1)

 The seal should have a distance of 6 mm to the top edge of the window and close up flush on both sides of the windshield (1)..

28

Align windshield (1) in body opening with crane and suction lifting device

AR67.10-P-1000-04TS


Helper required to guide windshield (1).
Otherwise adjacent body parts and windshield (1) can be damaged.

 The inside of the upper seal strip on the windshield (1) should make contact with the front edge of the roof.

Distance between top edge of window and transition between rabbet and front edge of roof

*BE67.10-P-1001-01G

 Feeler gauge

*129589032100

29

Prepare windshield (1) for installation

AR67.10-P-1000-03TS


The bonding areas on the windshield must be free of dust and grease.
Otherwise adhesion problems can occur when installing.

Repair kit for installing windshields, 1-component adhesive

*BR00.45-Z-1135-02A

Cleaner

*BR00.45-Z-1025-04A

White adhesive tape

*BR00.45-Z-1107-02A

30

Apply adhesive material

AR67.10-P-1000-08P


Install windshield (1) within 10 min after applying adhesive to body flange.
Otherwise the adhesive force of the glue starts to decrease.

 Uniformly apply adhesive material in shape of bead at a height of approx. 13 mm.

Glazing repair kit, 2-component adhesive

*BR00.45-Z-1015-02A

Repair kit for installing windshields, 1-component adhesive

*BR00.45-Z-1135-02A

 Adapter

*000589866300

31

Insert windshield (1) with crane and vacuum lifter and align

AR67.10-P-1503-01TS


Ensure that at least one vehicle door remains open while the adhesive material cures.
When a vehicle door is closed, the vibration to the body can change the installation position of the windshield (1).

 The inside of the upper seal strip on the windshield (1) should make contact with the front edge of the roof.

32

Connect electrical connector for heated windshield

33

Clip in drill rail (4)

 Ensure that drip rails (4) are seated correctly in clips. Ensure that clips are seated correctly in roof paneling.

34

Install air/water duct

35

Install wiper arms

AR82.30-P-6100CW

36

Install multifunction camera

Model 212
with code 476 (Lane keeping assist)
with code Z04 (Light armoring)
Model 212
with code 513 (Speed Limit Assist)
with code Z04 (Light armoring)
Model 212
with code 608 (Adaptive Highbeam Assist)
with code Z04 (Light armoring)

AR54.21-P-3000EW

37

Install infrared camera

Model 212
with code 610 (Night view assist)
with code Z04 (Light armoring)

AR54.30-P-3000SX

38

Insert rain/light sensor and connect

AR82.30-P-7800CW

39

Install splinter protection plate

 Splinter protection plate should contact with the windshield (1) all the way around.

 Nut/bolt, splinter guard to rain/light sensor guard plate

*BA63.20-P-1004-01B

40

Fasten inside rearview mirror

AR68.40-P-0001SX

41

Install cover of splinter protection plate

42

Install left and right sun visor

43

Install left and right A-pillar paneling

44

Route wiring harness

 Model 212
with code Z04 (Light armoring)
with code Z17 (Heated windscreen)
Route using cord installed during removal.

45

Install contacts in connector and connect electrical connectors for heated windshield

Model 212
with code Z04 (Light armoring)
with code Z17 (Heated windscreen)

AR00.19-P-0120-13A

 New passenger car wiring harness repair kit

*220589049900

 Wiring harness repair kit, basic

*000589139900

 Blade holder with clamping pliers

*220589019950

 LSK 8_blade

*220589019956

46

Install floor covering in front passenger footwell

Model 212
with code Z04 (Light armoring)
with code Z17 (Heated windscreen)

47

Install right lower A-pillar paneling

Model 212
with code Z04 (Light armoring)
with code Z17 (Heated windscreen)

48

Fasten edge guard in area of right lower A-pillar paneling

Model 212
with code Z04 (Light armoring)
with code Z17 (Heated windscreen)

49

Install right front door sill

Model 212
with code Z04 (Light armoring)
with code Z17 (Heated windscreen)

AR68.30-P-4100EW

50

Remove protective foil on inside of windshield (1)

51

Remove protective film from dashboard, center console and front seats

52

Code adaptation of rain sensor and light sensor amplification factor and select type of windshield



AD00.00-P-2000-04A

53

Check all electrical consumers in area repaired for proper function

Test and adjustment values for windshield

Number

Designation

Model 212

BE67.10-P-1001-01G

Distance between top edge of window and transition between rabbet and front edge of roof

Dimension "a"

mm

5 (1)

For picture, see

-

 Columns

Number

Designation

Model 212
with code Z04 (Light armoring)

BA63.20-P-1004-01B

Nut/bolt, splinter guard to rain/light sensor guard plate

Nm

12

Repair materials

Number

Designation

Order number

BR00.45-Z-1012-07A

Primer stick

A 000 986 27 50

BR00.45-Z-1015-02A

Glazing repair kit, 2-component adhesive

A 220 670 00 93

BR00.45-Z-1025-04A

Cleaner

A 005 989 19 71

BR00.45-Z-1107-02A

White adhesive tape

A 006 989 09 85

BR00.45-Z-1135-02A

Repair kit for installing windshields, 1-component adhesive

A 221 670 81 01

BR00.45-Z-1142-02A

Adhesive parts kit (with heptane cleaner)

A 451 989 01 71