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

MODEL 219.3 

Fig 1: Identifying Windshield Remove/Install Components
G10768295Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES

18.6.08 Note on painting in the glazing area added Step 9  
REMOVING Removing     
DANGER Risk of injury  due to tear or warming up of cutting wire and through glass splinters when cutting out glued windows Wear protective gloves and safety glasses. AS67.00-Z-0004-01A
DANGER Risk of injury  caused by moving parts that can pinch, crush or, in extreme cases even sever extremities. Always remove ignition key when working on windshield wiper mechanism. AS82.30-Z-0001-01A
NOTES Notes on removal/installation of windshield   AH67.10-P-1000-01P
1.1 Prepare adhesive cartridge IMPORTANT When using 2-component repair kit for installing glued windows.
Cartridge gun		 AR67.10-P-1000-07Y
Repair kit *BR00.45-Z-1015-02A 
1.2 Prepare 1-component adhesive cartridge IMPORTANT When using 1-component repair kit for installation without booster. AR67.10-P-1000-12SX
SPECIAL TOOL Intermediate piece
Cartridge preheater, cartridge gun		 Fig 2
Repair kit *BR00.45-Z-1089-02A 
2 Remove inside rearview mirror   AR68.40-P-0001TX
3 Remove plate for fastening inside rearview mirror    
4 Remove rain/light sensor (B38/2)   AR82.30-P-7800TX
5 Remove water repellent IMPORTANT Left and right side AR88.85-P-2100TX
6 Remove water collector   AR83.25-P-1402TX
7 Cut out windshield (3) with roll out 2004 window removal tool (1) Roll out 2004 window removal tool
Suction lifting device		 AR67.10-P-1000-11SX
8 Remove windshield (3) from body with cup suction tools IMPORTANT Aid of helper required.
Suction lifting device		  
INSTALLING Install     
9 Prepare body flange for installation of window   AR67.10-P-1501-01Y
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. AH98.00-P-9408-06A
Wet and dry vacuum cleaner  
Repair kit *BR00.45-Z-1015-02A 
Repair kit *BR00.45-Z-1089-02A 
Touch-up pencil *BR00.45-Z-1012-07A 
Hepox 2K EP primer filler 4017 (Spray Max) *BR00.45-Z-1050-07A 
10 Replace rubber window spacers IMPORTANT Do not remove protective foil. AR67.10-P-1000-02Y
11 Install cup suction tool on new windshield (3) Suction lifting device  
12 Insert windshield (3) into body. IMPORTANT Aid of helper required.
Suction lifting device		  
13 Align windshield (3) with body opening IMPORTANT Observe gap AR67.10-P-1000-04Y
SPECIAL TOOL Feeler gauge Fig 3
Distance between edge of sprayed area at windshield and front edge of roof *BE67.10-P-1001-01C 
14 Remove windshield (3) from body. IMPORTANT Aid of helper required.
Suction lifting device		  
15 Prepare windshield (3) for installation IMPORTANT Install foam rubber insulation on windshield (3) AR67.10-P-1000-03Y
IMPORTANT Allow primer to air-dry for a minimum of 10 minutes.  
Repair kit *BR00.45-Z-1015-02A 
Repair kit *BR00.45-Z-1089-02A 
16 Remove protective foil from rubber window spacers.    
17 Open side window in driver door NOTES During curing time, this prevents the windshield (3) from being pressed outward by the air pressure when the doors are closed  
18 Apply adhesive material NOTES Install windshield (3) within 10 minutes before adhesive force of adhesive material starts to decrease. AR67.10-P-1000-08Y
IMPORTANT Apply adhesive bead uniformly approx. 13 mm high.  
Cartridge gun  
Repair kit *BR00.45-Z-1015-02A 
Repair kit *BR00.45-Z-1089-02A 
19 Insert windshield (3) into body and install. IMPORTANT Helper required. The curing time of the adhesive material is approx. 1 h, calculated from the time the windshield (3) is installed.
Suction lifting device		 AR67.10-P-1503-01Y
20 Remove cup suction tool from new windshield (3).    
21 Install water collector   AR83.25-P-1402TX
22 Install water repellent IMPORTANT Left and right side AR88.85-P-2100TX
23 Install rain/light sensor   AR82.30-P-7800TX
24 Install plate for fastening inside rearview mirror    
25 Install inside rearview mirror   AR68.40-P-0001TX
26 Perform basic programming   AR00.19-P-0200TX
27 Read out fault memory and erase IMPORTANT Stored faults which may be caused by removal, test work, removed lines or a simulation, must be processed and erased in the fault memories after completing the work.  
REFER TO SELF-DIAGNOSTIC SYSTEMS Connect STAR DIAGNOSIS and read out fault memory   AD00.00-P-2000-04A
28 Carry out function check    
29 Clean windshield (3) and passenger compartment    
30 Close side window in driver door NOTES Only after curing time has expired, otherwise the windshield (3) can be pressed outward by the air pressure when the doors are closed.  
CHECK VALUES FOR WINDSHIELD

Number Designation Model 219
BE67.10-P-1001-01C Distance between edge of sprayed area at windshield and front edge of roof mm 2
Fig 2: Identifying Intermediate Piece (000 589 86 63 00)
G10768296Courtesy of MERCEDES-BENZ USA
Fig 3: Identifying Feeler Gauge (129 589 03 21 00)
G10768297Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1015-02A Repair kit, glazing, installing window, 2-component adhesive A 220 670 00 93
BR00.45-Z-1089-02A Repair kit, installing window, 1-component adhesive, replaced by: A 221 670 81 01 A 221 670 21 01
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
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