51 31 000 Removing and installing/replacing windscreen

Special tools required:

IMPORTANT: The "INSTRUCTIONS ON BONDING WINDSCREEN " serve as the basis for this repair instruction and must be observed without fail.
Cover front side panel with protective covers.

NOTE: Removal is performed with ROLL OUT 2000 . Only use an oscillating blade when replacing the windscreen.

Necessary preliminary work:

Remove INSIDE MIRROR
Remove SUN VISORS and counter supports
Remove PANELS FOR ROOF PILLAR at front
Remove COVER FOR COWL PANEL

Replacement:

Remove windscreen rubber surround
Remove retaining strip for cowl panel cover
Tape off body aperture all round with fabric adhesive tape

IMPORTANT: Tape off body in area of piercing point with fabric adhesive tape (1).

Push wire starter (2) from ROLL OUT 2000 through adhesive bead.

Fig 1: Pushing Wire Starter Through Adhesive Bead

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Replacement only:

Mount U-shape blade on tool:

24 mm blade length.

Regrind blade with a grindstone while machine is running (new blades also).

Carefully insert blade between body aperture and windscreen.

Guide handle of knife parallel to windscreen.

Cut through adhesive bead as closely as possible to windscreen.

Fig 2: Identifying U-Shape Knife

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NOTE: When cutting is carried out at the bottom in the event of replacement, the engine compartment lid must be in the service position.

Fig 3: Moving Engine Compartment Lid Into Service Position

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Move engine compartment lid into service position.

Cut through windscreen adhesive bead at bottom.

Lift out windscreen with special tools 51 3 010 .

Pull off adhesive tapes all round.

Installation note:

No spacer buffers are fitted because a retaining strip is mounted at the bottom.

If necessary, replace defective expanding foam tape.

Replacement:

Version with visible vehicle identification number:

Stick 60 mm long expanding foam tape 5 mm above viewing window for VIN onto ceramic layer.

Overview of windscreen bonding:

Fig 4: Overview Of Windscreen Bonding

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Attach special tool 51 3 010 twice to tool trolley. Moisten suction surfaces and tension windscreen from outside.

If reusing removed windscreen, remove residual adhesive down to 0.5 mm.

If necessary, fit new retaining strip (5) and rubber frame (6), paying attention to center markings in the process.

Insert positioner (8) for retaining strip (5) must be removed after it has been fitted on the windscreen but before the windscreen itself is installed.

If necessary, press expanding foam tape down with special hand roller tool 51 0 300 .

Virtually vertical part (B) of adhesive bead (1) must be positioned to rubber frame (6) and retaining strip (5).

Spread bead joint with special tool. 00 9 322

Fig 5: Identifying Distance Between Yellow Plastic Adhesive Tapes And Outside Corners Of Roof

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NOTE: Adhesive area for plastic adhesive tapes (1) must be free from grease and dust.

Stick two yellow plastic adhesive tapes (1) to roof at distance (A) from outside corners.

Length: 400 mm

A = 250 mm

Working on windscreen (1) carefully with special tool 51 3 010 :

Position windscreen at top
Align sides evenly
Insert at bottom and press down
Press upwards until seal rests evenly on roof
Secure in terms of height in this position at top with two yellow plastic adhesive tapes (2)

Fig 6: Holding Window Glass With Suction Lifter (51 3 010)

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Preload on top of windscreen to prevent wind noise:

Windscreen (1) must be lower than roof outer skin (2). This is the only way to prevent wind noises.

Position special tool 51 0 010 in middle of vehicle depending on measurement (A) and check underprotrusion of windscreen (1).

Windscreen underprotrusion (A):

A = 3 ± 0.5 mm

X = Measurement stages 1... 4 mm

Fig 7: Adjusting Window Glass

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