Remove/install front end cover

AR88.80-G-1000E

Remove/install front end cover

17.3.10



Removing

Danger!

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

1

Remove additional headlamp

AR82.10-G-4722E

2

afrom additional headlamp

3

Remove wiper arms

AR82.30-G-6100E

4

Remove grab handle from front end cover (1)

5

Remove fittings for windshield washer system on front end cover (1)

6

Remove front end panel (1)

 Obtain assistance from a second person.

Carefully lift front end cover (1) with long wedge and cut through old adhesive bead between front end (1) and firewall piece by piece



*115589035900



Clean

7

Clean firewall and front end cover (1)



Removing

8

Scrape adhesive down to approx. 1 mm on firewall and on front end cover (1) with scraper.

 After removing, observe the following to prevent faulty adhesion:

 Dirt, dust or grease should not be present on the adhesive bead scraped off.

 Do not touch adhesive bead with bare fingers after scraping off.

 Remove all loose residues from old adhesive bead.



Clean

9

Clean bonding surface on front end cover (1) and firewall with moist rag from repair kit.

 The bonding surfaces must be absolutely free of grease and dust.

*BR00.45-Z-1031-02A



Install

10

Dab minor damage on paint with primer.

 Precisely observe application instructions for primer, otherwise the adhesive force of the glue is not ensured.

*BR00.45-Z-1031-02A

11

Apply adhesive bead (2) to front end cover (1)

*BR00.45-Z-1031-02A

12

Install front end cover (1)

 Fix front end cover (1) in place with bolts (3) and washers on firewall and with adhesive tape (4) on windshield.

The curing time (drive-away time) is

approx. 2 h, calculated from the time the front end cover (1) is inserted.

13

Install fittings for windshield washer system on front end cover (1)

14

Install grab handles on front end cover (1)

15

Install wiper arms

AR82.30-G-6100E

16

Install bracket for additional headlamp

17

Install additional headlamps

AR82.10-G-4722E

Number

Designation

Order number

BR00.45-Z-1031-02A

Repair kit, installing window 500662 01/03/05/07/09/11

A 973 670 00 93