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

MODEL 221.1 with CODE (Z07) Top protection 

Fig 1: Identifying Windshield, Wiper Park Heater Connector And Heated Windshield Connector
G07583896Courtesy of MERCEDES-BENZ USA
Fig 2: Identifying Windshield, Roof Splinter Guard Strip And A-Pillar Splinter Guard Strip
G07583897Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES

18.7.08 Note on painting in the glazing area added Step 12  
REMOVING 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
DANGER 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 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. SPECIAL TOOL Long wedge Figure
7 Disconnect wiper park heater connector (X64/3) IMPORTANT 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
IMPORTANT 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 NOTES Masking prevents vehicle paint damage when cutting out windshield (1).  
    Adhesive tape *BR00.45-Z-1013-02B
10 Cover area of water collector with suitable protective film    
DANGER Risk of injury  caused by slipping when inserting blade in the multicutter 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 NOTES Helper required for guiding windshield (1), otherwise, adjacent body parts can be damaged.
Wet and dry vacuum cleaner gotis://P 00.12 06.0		 AR67.10-P-1000-01SXS 
    Window glazing device, FSC 1.6 gotis://K_67.0_01.0  
    Vacuum lifting device for special protection vehicles, cup suction tool gotis://K_67.0_03.0  
    Cutting blade, straight shape, Blade length 60 mm Order No.: 6 39 03 081 01 3 www.fein.com Cutting blade, L shape, blade length 25, 4 mm Order No.: 6 39 03 207 01 2 www.fein.com Cutting blade, L shape, blade length 19 mm Order no.: 6 39 03 208 01 0 www.fein.com  
    Adhesive tape *BR00.45-Z-1071-02A
    Cleaner *BR00.45-Z-1025-04A
12 Prepare body flange for installation of window NOTES 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 
NOTES 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 gotis://P_00.12_06.0		 AH98.00-P-9408-06A
    Bonding agent Sika primer 206 G+P *BR00.45-Z-1019-02A
    White adhesive tape *BR00.45-Z-1007-02B
    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    
INSTALLING Install     
14 Measure resistance of wiper heater on new windshield (1) IMPORTANT If the reading is outside of the tolerance range of 3.9 to 4.1 Q, do not install windshield (1).
Digital multimeter gotis://E_15/54_06.0		  
15 Measure resistance of heating foil on new windshield (1) On vehicles with code (597) Heated windshield
IMPORTANT If the reading is outside of the tolerance range of 0.64 to 0.89 , do not install windshield (1).
Digital multimeter gotis://E_15/54_06.0		  
16 Align windshield (1) in body opening with suction lifting device NOTES Aid of a helper is required for guiding the windshield (1), otherwise adjacent body parts and the windshield (1) can be damaged. AR67.10-P-1000-04SXS 
    NOTES 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.
IMPORTANT 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.
SPECIAL TOOL Feeler gauge		 Figure
    Loctite 577
Vacuum lifting device for special protection vehicles gotis://K_67.0_03.0		 *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 NOTES 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 gotis://K_67.0_03.0		 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 
    SPECIAL TOOL Intermediate piece
Cartridge gun gotis://K 67.0 02.0		 Figure
    Adhesive Sika 555 *BR00.45-Z-1009-02B
21 Apply adhesive material NOTES 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 gotis://K_67.0_02.0		 AR67.10-P-1000-08SXS 
    Adhesive Sika 555 *BR00.45-Z-1009-02B
22 Position windshield (1) and align NOTES 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.
IMPORTANT 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 gotis://K_67.0_03.0		 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.
NOTES To adjust the gap dimension, use only bolts and spacer washers approved in the "Electronic Part Catalog", otherwise the protective effect is not ensured.		 AR67.10-P-1000-13SXS 
    NOTES 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).
TORQUE SPECIFICATION Bolt, splinter guard on gap cover		 *BA63.20-P-1002-01B
    TORQUE SPECIFICATION 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. NOTES Always maintain curing time of approx. 2 h for adhesive material, otherwise the adhesive force of the glued connection is ensured.
IMPORTANT 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 IMPORTANT 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.		  
REFER TO SELF-DIAGNOSTIC SYSTEMS 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)
G07583898Courtesy of MERCEDES-BENZ USA
Fig 4: Identifying Long Wedge (115 589 03 59 00)
G07583899Courtesy of MERCEDES-BENZ USA
Fig 5: Identifying Feeler Gauge (129 589 03 21 00)
G07583900Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1067-01A Loctite 577 Henkel Loctite Deutschland GmbH Arabellastrasse 17 81925 Munchen Germany Tel. +49 899268-0 Fax + 49 899101978 www.Loctite.de
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 Stuttgarter Strasse 139 72574 Bad Urach Germany Tel. +49 7125 940-761 Fax +49 7125 940-763 www.sika-industry.de
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-1007-02B White adhesive tape A 006 989 09 85
BR00.45-Z-1009-02B Adhesive Sika 555 Sika Deutschland GmbH Stuttgarter Strasse 139 72574 Bad Urach Germany Tel. +49 7125 940-761 Fax +49 7125 940-763 www.sika-industry.de
BR00.45-Z-1013-02B 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 Fritz-Hecker-Str. 47-107 50968 Koln Germany Tel. +49 221 370606 Fax. +49 221 3706410 www.spieshecker.com
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