Remove/install seal on crossmember above windshield - AR77.50-P-4050V

MODEL 171.4 

Fig 1: Identifying Seal On Crossmember Components (1 Of 2)

Courtesy of MERCEDES-BENZ USA

Fig 2: Identifying Seal On Crossmember Components (2 Of 2)

Courtesy of MERCEDES-BENZ USA

Fig 3: Identifying Gasket And Roller

Courtesy of MERCEDES-BENZ USA

MODIFICATION NOTES

29.10.04

Repair method updated

All steps

	Remove
1	Remove outer paneling on left and right A-pillar (3)		AR88.80-P-8500V
2	Remove expansion clip (2) from left and right A-pillar (3)
3	Remove seal (1) from roof frame (4) and A-pillars (3)
	Cleaning
4	Remove sealant residues and clean sealing surfaces on roof frame (4) and on A-pillar (3)	The sealing surfaces must be free of oil and grease. Otherwise leakage is possible. Observe drying time for cleaning agent It is not necessary to clean the seal (1) because it is always replaced after removal
		Cleaner	*BR00.45-Z-1025-04A
	Install
5	Route dia. 4 mm sealing profile (7) in center of roof frame	Helper for holding 4 mm dia. sealing cord (7) required Do not touch dia. 4 mm sealing profile (7) with bare fingers Length of dia. 4 mm sealing profile (7) approx. 1120 mm. Observe connection of dia. 4 mm sealing profile (7) to dia. 6 mm sealing profile (5).
		Sealing cord	*BR00.45-Z-1060-01A
6	Route dia. 6 mm sealing profile (5) along both A-pillars (3) and on roof frame (4)	6 mm dia. sealing cord (5) should overlap 4 mm dia. sealing cord (7) clearly. Otherwise leakage can occur later Do not touch dia. 6 mm sealing profile (5) with bare fingers Length of dia. 6 mm sealing profile (5) approx. 620 mm. The dimensions (A) should be approx. 8 mm Route dia. 6 mm sealing profile (5) below pull-in nut (8)
		Sealing cord	*BR00.45-Z-1021-01A
7	Route dia. 4 mm sealing profile (9) along both A-pillars (3)	Do not touch dia. 4 mm sealing profile (9) with bare fingers Length of dia. 4 mm sealing profile (9) approx. 100 mm. Observe connection (arrow D) of dia. 4 mm sealing profile (9) to dia. 6 mm sealing profile (5) Gap (C): approx. 10 mm
		Sealing cord	*BR00.45-Z-1060-01A
8	Route dia. 6 mm sealing profile (6) along both corners on A-pillars (3)	Do not touch dia. 6 mm sealing profile (6) with bare fingers Length of dia. 6 mm sealing profile (6) approx. 50 mm.
		Sealing cord	*BR00.45-Z-1021-01A
9	Position seal (1) to roof frame (4) with both corner elements (arrows B), align corner elements (arrows B) on pull-in nuts (8) and press seal (1) to roof frame (4) toward center.	Use new seal (1) Helper is required for positioning and aligning seal (1) One hole each is present on the corner brackets (arrows B) for the bolt for mounting the outer paneling to the A-pillar (3). The corner elements (arrows B) are aligned to the pull-in nuts (8) with these holes
10	Press seal (1) to A-pillars (3) and roof frame (4) over entire length with roller (10)	Press seal (1) down in routing area of sealing cords (5, 6, 7, 9)
			Fig 5
11	Cut ends of dia. 4 mm sealing profile (9) extending beyond both A-pillars (3) flush with seal (1) using a mounting wedge and remove.		Figure
12	Install expansion clips (2)	Replace damaged expanding clips (2)
13	Install paneling on left and right outer A-pillar (3)		AR88.80-P-8500V
14	Clean seal (1) and adjacent body parts	While cleaning check whether seal (1) is seated correctly
		Cleaner	*BR00.45-Z-1025-04A
15	Perform rain test

Fig 4: Identifying Mounting Wedge (110 589 03 59 00)

Courtesy of MERCEDES-BENZ USA

Fig 5: Identifying Roller (171 589 06 63 00)

Courtesy of MERCEDES-BENZ USA

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1021-01A	Sealing cord	A 001 987 73 46
BR00.45-Z-1060-01A	Sealing cord	A 001 987 42 46
BR00.45-Z-1025-04A	Cleaner	A 005 989 19 71