Remove/install rear window - AR67.20-P-2000SXS

MODEL 221.1 with CODE (Z07) Top protection 

Fig 1: Identifying Rear Window Components (1 Of 3)

Courtesy of MERCEDES-BENZ USA

Fig 2: Identifying Rear Window Components (2 Of 3)

Courtesy of MERCEDES-BENZ USA

Fig 3: Identifying Rear Window Components (3 Of 3)

Courtesy of MERCEDES-BENZ USA

MODIFICATION NOTES

24.7.08

Note on painting in the glazing area added

Step 21

	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  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
	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	Fold down head restraints in rear.
2	Cover rear shelf and rear seats with suitable protective covers
3	Remove upper paneling on right C-pillar		AR68.30-P-4490SXS
4	Remove upper and lower paneling on left C-pillar	Do not remove belt end fitting.	AR68.30-P-4490SXS
5	Cut off electrical line (2) for ground (heated rear window) (W13) and electrical line (3) connected to rear window interference suppression capacitor (C3) as close as possible to installed rear window (1)	Ensure that the ignition is switched off, otherwise the electrical system of the vehicle can be damaged.
6	Mask off body parts next to rear-end window (1)	Masking prevents damaging the vehicle paintwork when cutting out the rear window (1).
		Adhesive tape	*BR00.45-Z-1013-02B
7	Cover front area of trunk lid with stable protective cover or mask off	The unprotected trunk lid can be damaged when the rear-end window (1) is cut out, removed and installed. Adhesive tape	*BR00.45-Z-1013-02B
8	Cut off profiled rubber seal (4) on left and right and at top with suitable blade flush with glass edge of rear-end window (1)
9	Cut through adhesive material at bottom of outer adhesive area (A)	Cutting blade, straight, blade length40 mm Order no.: 6 39 03 176 01 5 www.fein.com Window removal tool, FEIN FSC 1.6 gotis://K_67.0_01.0
10	Cut through adhesive material at side of left and right outer adhesive area (B)	Cutting blade, L-shape blade length 19 mm Order no.: 6 39 03 208 01 0 www.fein.com Window removal tool, FEIN FSC 1.6 gotis://K_67.0_01.0
11	Cut through adhesive material at top of outer adhesive area (C)	If a cutter with a longer blade is used, the antenna amplifier module for the rear window (A2/12) can be damaged. Cutting blade, L-shape blade length 38 mm Order no.: 6 39 03 209 01 4 www.fein.com Window removal tool, FEIN FSC 1.6 gotis://K 67.0 01.0
12	Mark with a wax pencil, left and right sides of rear-end window (1) with a scriber marking (5)	The mark (5) should be approx. 20 mm from the side glass edge of the rear-end window (1).
13	Mark with a wax pencil the top marking (6) on rear-end window (1)	The mark (6) should be approx. 40 mm from the upper glass edge of the rear-end window (1).
14	Scribe rear-end window (1) along markings (5, 6) with suitable glass cutter (12)	This results in a continuous predetermined fracture point on the rear-end window (1).
15	Apply adhesive tape (13) to middle of predetermined fracture point on rear-end window (1)	During the next operation step, the adhesive tape (13) serves as splinter guard.
		Adhesive tape	*BR00.45-Z-1071-02A
16	Knock off outer area of rear window (1) along predetermined fracture point with hammer and simultaneously vacuum out glass splinters.	Tap carefully in the area of the rear-end window antenna amplifier module (A2/12), otherwise, the rear-end window antenna amplifier module can be damaged (A2/12). Wet and dry vacuum cleaner gotis://P 00.12 06.0
17	Detach and remove adhesive tape (13) together with knocked off predetermined fracture points from rear window (1) and simultaneously vacuum out glass splinters	Mounting wedge Wet and dry vacuum cleaner gotis://P 00.12 06.0	Fig 5
18	Cut through adhesive material on inner adhesive areas (D)	When cutting through the inner adhesive areas (D), parts of the roof armor plate may be in the way of the cutter. In this case, it is necessary to shorten the cutter blade. Cutting blade, L-shape blade length 19 mm Order no.: 6 39 03 208 01 0 www.fein.com Window removal tool, FEIN FSC 1.6 gotis://K 67.0 01.0
19	Lift rear-end window (1) from body flange with crane and suction lifting device (14)	During this operation, it is necessary for a helper to guide the rear-end window (1), otherwise, adjacent body areas can be damaged. Vacuum lifting device for special protection vehicles gotis://K_67.0_03.0
20	Clean vehicle in working area	Wet and dry vacuum cleaner gotis://P_00.12_06.0
		If applicable, remove rear window to thoroughly clean the work area. Refer to: ↓ Remove/install and disassemble rear shelf	AR68.30-P-4580SXS
21	Prepare body flange for installation of window	The adhesive areas on the body flange must be absolutely free of dust and grease to prevent a decrease in the gluing force when installing the window.	AR67.20-P-2000-09SXS
	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.	AH98.00-P-9408-06A
		Wet and dry vacuum cleaner gotis://P 00.12 06.0 Bonding agent Sika primer 206 G+P	*BR00.45-Z-1019-02A
		Cleaner	*BR00.45-Z-1025-04A
		Touch-up pencil	*BR00.45-Z-1012-07A
		Hepox 2-component EP primer filler 4017 (Spray Max)	*BR00.45-Z-1050-07A
	Install
22	Test resistance of rear window heater on new rear-end window (1) on electrical lines (7, 8)	If the measuring result is outside of the tolerance range from 0.58 to 0.71 G, do not install rear-end window (1). Digital multimeter gotis://E_15/54_06.0
23	Check rear window antenna amplifier module (A2/12) for damage, replace damaged parts if required
24	Position electrical lines (7, 8) at the bottom edge of rear-end window (1) as shown and fix in place with one strip of adhesive tape (9) each, then fasten ends of line to inside of rear-end window (1) with adhesive tape.	Hold electrical lines (7, 8) in place, directly at edge. Otherwise, the electrical lines (7, 8) can be damaged when installing the rear-end window (1). Do not apply adhesive tape to polycarbonate foil to prevent damaging it.
		Adhesive tape	*BR00.45-Z-1071-02A
25	Align rear window (1) in body opening	Position vacuum lifting unit (14) in upper third of rear-end window (1), so that the lifted rear-end window (1) is parallel to the C-pillars, otherwise the edges of the rear-end window (1) can hit the body flange when inserting and break off. Observe gap between splinter guard strips and rear-end window (1). The gap dimension (C) should be in the tolerance range of approx. 1 to 3 mm.	AR67.20-P-2000-04SXS
		Distance between upper edge of shaped rubber gasket and rear edge of roof	*BE67.20-P-1001-01K
		Feeler gauge Vacuum lifting device for special protection vehicles gotis://K 67.0 03.0	Figure
26	Remove rear-end window (1) from body flange with aid of helper	Vacuum lifting device for special protection vehicles gotis://K_67.0_03.0
27	Separate headliner and lay down on front seat head restraints	If it has been determined that it is necessary to adjust the gap between the splinter guard strips and rear-end window (1).	AR68.30-P-4300SXS
28	Remove splinter guard strips from roof guard plate and splinter guard strips on gap covers on C-pillars	If it has been determined that it is necessary to adjust the gap between the splinter guard strips and rear-end window (1).
29	Prepare rear window (1) for installation	The adhesive areas on the rear-end window (1) must be absolutely free of dust and grease to prevent a decrease in the gluing force when installing the window.	AR67.20-P-1000-07SXS
		Vacuum lifting device for special protection vehicles gotis://K 67.0 03.0 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
30	Prepare adhesive cartridge		AR67.10-P-1000-07SXS
		Intermediate piece	Figure
		Cartridge gun gotis://K 67.0 02.0 Adhesive Sika 555	*BR00.45-Z-1009-02B
31	Apply adhesive material to rear-end window	Install rear-end window (1) on body	AR67.20-P-2000-08SXS
	(1)	flange within 10 minutes after applying glue, otherwise adhesive force of glue starts to decrease. Uniformly apply glue in shape of bead at a height of approx. 16 mm.
		Adhesive Sika 555	*BR00.45-Z-1009-02B
32	Install rear-end window (1) with suction lifting device (14), cup suction tools (15) and aid of helper, align and glue in.	Position vacuum lifting unit (14) in upper third of rear-end window (1), so that the lifted rear-end window (1) is parallel to the C-pillars, otherwise the edges of the rear-end window (1) can hit the body flange when inserting and break off or the glue beads can run.
		Do not perform any activities which could shake the vehicle during the curing time. The installation position of the rear window (1) can be changed by the body shaking. Then hold rear-end window (1) in place, as shown, on roof with strips of adhesive tape (10) Another helper is required on the inside of the vehicle to ensure that the electric lines (7, 8) are not pinched and do not come into contact with the adhesive material. Vacuum lifting device for special protection vehicles gotis://K 67.0 03.0
33	Adjust gaps between splinter guard strips and rear-end window (1)	If it has been determined that it is necessary to adjust the gap between the splinter guard strips and rear-end window (1).	AR67.20-P-2000-10SXS
		Use only bolts and spacer washers approved in the "Electronic Part Catalog" to adjust the gap dimension. Otherwise, the designed protective effect is not ensured. The gap between the splinter protection strip and the rear window (1) must be within a tolerance range of approx. 1 to 3 mm. If the rear-end window (1) is in contact with the splinter guard strip, tension is produced which could lead to damage to the rear-end window (1).
		Bolt, splinter guard on gap cover	*BA63.20-P-1002-01B
		Bolt, splinter guard on roof protection plate	*BA63.20-P-1003-01B
34	Unfasten left and right luggage compartment lining until the installed control units are accessible.	The number of control unit differs according to the equipment installed.	AR68.30-P-4600SXS
35	Cover control units with watertight foil.	Otherwise penetrating water can damage the control unit when performing the leak test.
36	Close trunk lid
37	Check cured outer adhesive bead of rear window (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. Spray rear-end window (1) with rain water or solution of soap and water starting at upper body flange and check for leakage. A leaky adhesive bead is indicated by water entering the trunk below the rear-end window (1). Remove water which has leaked in. If event of leakage, dry adhesive bead and then seal adhesive bead from outside with glue.
		Adhesive	*BR00.45-Z-1007-02A
38	Install headliner	If gap between roof splinter guard strip and rear-end window (1) has been adjusted.	AR68.30-P-4300SXS
39	Route electrical lines (7, 8) parallel to the electrical lines (2, 3) cut through during removal.	Ensure that electrical lines (7, 8) are routed without chafing, otherwise electrical lines (7, 8) can be damaged. Fix electrical lines (7, 8) in place, with strips of adhesive felt (11), as shown.
40	Disconnect electrical lines (2, 3) cut through, unscrew and remove
41	Connect electrical lines (7, 8) and screw down tight
42	Remove transport protection foil from inside of rear-end window (1)
43	Install paneling on left and right C-pillars		AR68.30-P-4490SXS
44	Clean rear window (1)	Cleaner	*BR00.45-Z-1025-04A

TEST VALUES FOR LIFTGATE WINDOW, REAR WINDOW

Number	Designation			Model 221
BE67.20-P-1001-01K	Distance between upper edge of shaped rubber gasket and rear edge of roof	Dimension "A"	mm	5 (±0.5)
		See picture		-

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 4: Identifying Intermediate Piece (000 589 86 63 00)

Courtesy of MERCEDES-BENZ USA

Fig 5: Identifying Mounting Wedge (110 589 03 59 00)

Courtesy of MERCEDES-BENZ USA

Fig 6: Identifying Feeler Gauge (129 589 03 21 00)

Courtesy of MERCEDES-BENZ USA

REPAIR MATERIALS

Number	Designation	Order number
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-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 2-component 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