Remove/install windshield - AR67.10-P-1000SXS

MODEL 221.1 with CODE (Z07) Top protection 

Fig 1: Identifying Windshield Remove/Install Components (1 Of 2)

Courtesy of MERCEDES-BENZ USA

Fig 2: Identifying Windshield Remove/Install Components (2 Of 2)

Courtesy of MERCEDES-BENZ USA

MODIFICATION NOTES

18.7.08

Note on painting in the glazing area added

Step 12

	Removing
	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
	Risk of injury  from pinching and crushing hands and feet when working on windows.	Secure windows against dropping; use only specified lifting tools; wear safety shoes.	AS67.00-Z-0003-01A
	Notes on avoiding damage to windows installed in special high-security vehicles		AH67.00-P-0003-01FB
1	Cover dashboard, center console and front seats with suitable protective foil
2	Remove night view assist camera (B84/2)	On vehicles with code (610) Night View Assist	AR54.30-P-3000SX
3	Remove left and right A-pillar paneling
4	Remove wiper arms		AR82.30-P-6100SX
5	Remove water collector
6	Unclip left and right drip rail and remove.	Long wedge	Figure
7	Disconnect wiper park heater connector (X64/3)	Fasten wiring harness remaining on windshield (1) to windshield (1) with suitable adhesive tape.
8	Disconnect heated windshield connector (X92)	On vehicles with code (597) Heated windshield Fasten wiring harness remaining on windshield (1) to windshield (1) with suitable adhesive tape.
9	Mask off left and right A-pillar and front edge of roof in connection area with adhesive tape	Masking prevents vehicle paint damage when cutting out windshield (1).
		Adhesive tape	*BR00.45-Z-1113-02A
10	Cover area of water collector with suitable protective film
	Risk of injury  caused by slipping when inserting blade in the multi cutter and by glass 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
11	Cut out windshield (1) and lift from body flange with crane and suction lifting device	Helper required for guiding windshield (1), otherwise, adjacent body parts can be damaged. Wet and dry vacuum cleaner Window glazing device, FSC 1.6 Vacuum lifting device for special protection vehicles, cup suction tool Cutting blade, straight shape, Blade length 60 mm Order No.: 6 39 03 081 01 3 Cutting blade, L shape, blade length 25, 4 mm Order No.: 6 39 03 207 01 2 Cutting blade, L shape, blade length 19 mm Order no.: 6 39 03 208 01 0	AR67.10-P-1000-01SXS
		Adhesive tape	*BR00.45-Z-1071-02A
		Cleaner	*BR00.45-Z-1025-04A
12	Prepare body flange for installation of window	The adhesive area on the body flange and reinforcements must be absolutely free of dust and grease to prevent adhesion problems for the adhesive material when installing windows.	AR67.10-P-1501-01SXS
	General notes about painting the body flange in the glazing area	Pay attention to notes concerning the preparation of new parts such as the A-pillar, the roof or the side walls. Wet and dry vacuum cleaner	AH98.00-P-9408-06A
		Bonding agent Sika primer 206 G+P	*BR00.45-Z-1019-02A
		White adhesive tape	*BR00.45-Z-1107-02A
		Cleaner	*BR00.45-Z-1025-04A
		Touch-up pencil	*BR00.45-Z-1012-07A
		Hepox 2K EP primer filler 4017 (Spray Max)	*BR00.45-Z-1050-07A
13	Remove adhesive tape on A-pillars and front edge of roof
	Install
14	Measure resistance of wiper heater on new windshield (1)	If the reading is outside of the tolerance range of 3.9 to 4.1 Ω, do not install windshield (1). Digital multimeter
15	Measure resistance of heating foil on new windshield (1)	On vehicles with code (597) Heated windshield If the reading is outside of the tolerance range of 0.64 to 0.89 Ω, do not install windshield (1). Digital multimeter
16	Align windshield (1) in body opening with suction lifting device	Aid of a helper is required for guiding the windshield (1), otherwise adjacent body parts and the windshield (1) can be damaged. Replace and seal bolts intended to adjust height of windshield (1) in body opening on left and right of lower body flange to prevent water from penetrating into passenger compartment. The gap between the roof splinter guard strip (2) and the windshield (1) and between the A-pillar splinter guard strips (3) and windshield (1) must be within a tolerance range of approx. 1 to 3 mm. The inside of the apex seal on the windshield (1) must make contact with the front edge of the roof.	AR67.10-P-1000-04SXS
		Feeler gauge	Figure
		Loctite 577 Vacuum lifting device for special protection vehicles	*BR00.45-Z-1067-01A
17	Remove headliner and put down on head restraints	If it was determined that the gap between the roof splinter guard strip (2) and windshield (1) requires adjustment.	AR68.30-P-4300SXS
18	Remove roof splinter guard strip (2) on roof guard plate and A-pillar splinter guard strips (3) on gap covers on A-pillars	If it was determined that the gap between the roof splinter guard strip (2) and windshield (1) or between the A-pillar splinter guard strips (3) and windshield (1) requires adjustment.
19	Prepare windshield (1) for glazing	The adhesive areas on the windshield (1) must be absolutely free of dust and grease to prevent adhesion problems with the adhesive material when installing the window. Vacuum lifting device for special protection vehicles, cup suction tool	AR67.10-P-1000-03SXS
		Bonding agent Sika primer 206 G+P	*BR00.45-Z-1019-02A
		Sika activator	*BR00.45-Z-1090-02A
		Cleaner	*BR00.45-Z-1025-04A
20	Prepare adhesive cartridge		AR67.10-P-1000-07SXS
		Intermediate piece Cartridge gun	Figure
		Adhesive Sika 555	*BR00.45-Z-1109-02A
21	Apply adhesive material	Install windshield (1) on body flange within 10 minutes after applying adhesive material, otherwise adhesive force of glue starts to decrease. Uniformly apply glue in shape of bead at a height of approx. 16 mm. Cartridge gun	AR67.10-P-1000-08SXS
		Adhesive Sika 555	*BR00.45-Z-1109-02A
22	Position windshield (1) and align	Do not perform any activities which could shake the vehicle during the curing time. Physical shocks to the body can change the installation position of the windshield (1) and the windshield (1) can be damaged. The inside of the top apex seal of the windshield (1) should make contact with the front edge of the roof. Vacuum lifting device for special protection vehicles, cup suction tool	AR67.10-P-1503-01SXS
23	Adjust gap between roof splinter guard strip (2) and windshield (1) or between A-pillar splinter guard strips (3) and windshield (1)	If it was determined that the gap between the roof splinter guard strip (2) and windshield (1) or between the A-pillar splinter guard strips (3) and windshield (1) requires adjustment. To adjust the gap dimension, use only bolts and spacer washers approved in the "Electronic Part Catalog", otherwise the protective effect is not ensured. The gap between the roof splinter guard strip (2) and the windshield (1) and between the A-pillar splinter guard strips (3) and windshield (1) must be within a tolerance range of approx. 1 to 3 mm. If the windshield (1) is in contact with the roof splinter guard strip (2) or A-pillar splinter guard strip (3), tension results which can lead to damage to the windshield (1).	AR67.10-P-1000-13SXS
		Bolt, splinter guard on gap cover	*BA63.20-P-1002-01B
		Bolt, splinter guard on roof protection plate	*BA63.20-P-1003-01B
24	Remove protective foil in area of water collector
25	Connect heated windshield connector (X92)	On vehicles with code (597) Heated windshield
26	Connect wiper park heater connector (X64/3)
27	Check cured outer adhesive bead of windshield (1) for leakage, seal if applicable.	Always maintain curing time of approx. 2 h for adhesive material, otherwise the adhesive force of the glued connection is ensured. Close engine hood and spray windshield (1) starting at upper body flange with rain water or solution of water and soap and check for leakage, if applicable dry leaky points on adhesive bead and then seal adhesive bead from outside with adhesive.
		Adhesive	*BR00.45-Z-1007-02A
28	Clip in drip rail
29	Install water collector
30	Install wiper arms		AR82.30-P-6100SX
31	Install headliner	If the gap between the roof splinter guard strip (2) and windshield (1) or between the A-pillar splinter guard strips (3) and windshield (1) was adjusted.	AR68.30-P-4300SXS
32	Install A-pillar paneling
33	Remove protective foil on inside of windshield (1)
34	Install night view assist camera	On vehicles with code (610) Night View Assist.	AR54.30-P-3000SX
35	Remove protective film from dashboard, center console and front seats
36	Clean windshield (1)
37	Close engine hood and driver door and initialize rain/light sensor with STAR DIAGNOSIS	Perform initialization of the rain/light sensor with engine hood and driver door closed. The following variants are available in STAR DIAGNOSIS: up to identification 07 09 03787 as of identification 07 09 03788 The identification is located on the windshield (1) at the bottom left. The first number block of the identification stands for the production year (07 for 2007), the second number block for the production month (09 for September) and the third number block for the serial number.
	Connect STAR DIAGNOSIS and read out fault memory		AD00.00-P-2000-04A

PILLARS

Number	Designation		Model 221 with code Z07/Z07+Z19
BA63.20-P-1002-01B	Bolt, splinter guard on gap cover	Nm	8
BA63.20-P-1003-01B	Bolt, splinter guard on roof protection plate	Nm	8

Fig 3: Identifying Intermediate Piece (000 589 86 63 00)

Courtesy of MERCEDES-BENZ USA

Fig 4: Identifying Long Wedge (115 589 03 59 00)

Courtesy of MERCEDES-BENZ USA

Fig 5: Identifying Feeler Gauge (129 589 03 21 00)

Courtesy of MERCEDES-BENZ USA

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1067-01A	Loctite 577	Henkel Loctite Deutschland GmbH
BR00.45-Z-1007-02A	Adhesive, windows 310 ml TEROSTAT MS 930	A 005 989 61 71
BR00.45-Z-1019-02A	Bonding agent Sika primer 206 G+P	Sika Deutschland GmbH
BR00.45-Z-1071-02A	Adhesive tape roll, gray Tesa tape, 50 meters 0.3X50, 236 mm	A 001 989 17 85
BR00.45-Z-1090-02A	Sika activator	A 005 989 58 71
BR00.45-Z-1107-02A	White adhesive tape	A 006 989 09 85
BR00.45-Z-1109-02A	Adhesive Sika 555	Sika Deutschland GmbH
BR00.45-Z-1113-02A	Adhesive tape, air reservoir tensioning strap	A 655 989 04 85
BR00.45-Z-1025-04A	Cleaner	A 005 989 19 71
BR00.45-Z-1012-07A	Primer stick	A 000 986 27 50
BR00.45-Z-1050-07A	Hepox 2K EP primer filler 4017 (Spray Max)	Spies Hecker GmbH