51 31 200 Removing and installing/replacing rear window

Special tools required:

51 0 010

IMPORTANT: The following notes form the basis for these repair instructions and must be adhered to at all times:

Read NOTES ON WINDOW BONDING
GENERAL PROCEDURE for dismantling/installing bonded window glass

Cover rear side panels with protective covers.

When reusing the rear window:

Do not damage lines for heated rear window/-aerial.

NOTE: Removal is performed with ROLL OUT 2000 .

Only use an oscillating blade when replacing the windscreen.

Necessary preliminary tasks:

Remove TRIM PANELS FOR ROOF PILLAR AT REAR left/right
Remove ADDITIONAL BRAKE LIGHT
Partially lower HEADLINING AT REAR
Remove ROOF FRAME TRIM STRIP on left and right

Disconnect plug connections (1) on left and right.

Fig 1: Identifying Plug Connections

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Tape off edges of tailgate and body all round with fabric adhesive tape (e.g. Tesa).

Rear window
Adhesive bead
Body opening
Fabric adhesive tape

Fig 2: Identifying Rear Window, Adhesive Bead, Body Opening And Fabric Adhesive Tape

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

Push wire starter from ROLL OUT 2000 at line (1) through adhesive bead.

Fig 3: Identifying Wire Starter Adhesive Bead Line

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Only replace:

Have U-shape knife with 24 mm and 36 mm blade lengths ready.

Fit respective knife with required blade length:

24 mm = All round on rear window

36 mm = Recut window edges at bottom left and right

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

Fig 4: Identifying U-Shape Knife

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Insert knife carefully between tailgate and rear window.

Guide web of knife parallel to rear window.

Cut through adhesive bead as closely as possible to rear window.

Lift out rear window.

Pull off adhesive tapes all round.

Fitting spacer buffers:

Fig 5: Identifying Spacer Buffers

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IMPORTANT: To avoid rear window breakage and wind noises:

Completely remove remnants of removed spacer buffers and maintain installation location exactly.

The following spacer buffer is fitted.

6 x spacer buffers (5x5x20)

Installation position of spacer buffers (1) is specified on body side with markings (2).

Installation note:

If necessary, replace faulty UPPER REAR WINDOW COVER .

If necessary, replace faulty LOWER RUBBER FRAME for rear window.

Replacement:

Replace UPPER REAR WINDOW COVER .

If necessary, replace faulty LOWER RUBBER FRAME for rear window.

Overview of rear window bonding:

Fig 6: Overview Of Rear Window Bonding

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Secure cables of heated rear window/-aerial(s) with adhesive tape.

Fit rubber frames (6 and 7) in middle.

IMPORTANT: Observe cover pressure. The cover pressure represents the outer edge of the non-squashed adhesive bead. Lay adhesive bead within the cover pressure.

Fig 7: Positioning Special Tools (51 3 010) On Rear Window

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Carefully install rear window with SUCTION LIFTER (51 3 010) as follows:

Fix tailgate at 45°
Feed in rear window between tailgate and body
Position at top on roof edge
Align sides evenly
Insert at bottom and press down
Press upwards until sealing is uniformly contacting roof
Press down at bottom until rubber frame is uniformly in place
Secure rear window in this position with the two yellow plastic adhesive tapes

Installation note:

The required gap dimension from the window edge to the body aperture all round is:

5.5 mm

Adjusting pre-tension on rear window:

In order to avoid wind noises, rear window (1) must be lower than roof outer skin (2).

Position special tool 51 0 010 in center of vehicle depending on dimension (A) and check underprotrusion of rear window (1).

A = 3.5 mm

X = measurement stages 1... 4 mm

Fig 8: Checking Underprotrusion Of Rear Window

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