Remove/install windshield - AR67.10-P-1000MB: Notes

MODEL 220.175 /178 with CODE (Z04) Light armoring with CODE (Z07) Top protection 

Fig 1: Identifying Windshield Remove/Install Components - Model 220.175/178

	Operations involving work on glass panes and windows are potentially dangerous; use caution to avoid allowing hands or feet to become caught.	Secure windshield and windows from dropping down; use only the lifting tools specified for such operations. Wear safety shoes.	AS67.00-Z-0003-01A
	Instructions for avoiding damage to windows installed in special high-security vehicles		AH67.00-P-0003-01FB
	Remove
1	Unclip daylight sensor.		AR82.10-P-2400I
2	Remove wiper arms.		AR82.30-P-6100M
3	Remove water deflector
4	Remove paneling on outside of A-pillar.		AR88.80-P-8500M
5	Remove molding on windshield.		AR67.10-P-1200M
6	Remove paneling on A-pillar.		AR68.30-P-4050MC
7	Remove bracket for paneling on A-pillar.
8	Remove splinter guard on A-pillar.	Observe washers.
9.1	Remove A-pillar paneling in right footwell (4)	Only for code (Z04) light armoring with heated windshield.
10.1	Remove heated windshield connectors (2 and 3)	Only with heated windshield.
11	Remove overhead control panel control module		AR82.20-P-1000M
12	Remove font grab handles.	Observe washers
13	Remove sun visors
14	Loosen roof paneling in front area.
15	Cover instrument panel and roof paneling with sheeting.
16	Expose copper wires (arrow) and sand down both ends to bare metal.	In center area of left A-pillar.
17	Cover area around connections on A-pillar with adhesive tape.
18	Connect copper wires (arrow) to external power source	Use a transformer with a 12V output voltage or a separate fully charged 12V battery as an energy source. A spark must be produced when connecting otherwise current is not consumed. The heating time is approx. 10 minutes (windshield must heat noticeably).
19	Cut glue sealant from outside all the way around as deep as possible with blade
20	Remove windshield (1) from the body using suitable lifting equipment.	Suitable lifting equipment (crane, suction cup) is required for removing the windshield. Lift top part of windshield from body first, then pull up and out (see arrows). Cut through adhesive using a knife.
	Install
21	Remove residual adhesive from the body and windshield (1).	Repair paint damage on body flange.
22	Check windshield (1) for damage.
23	Insert and align windshield (1) as a trial installation.	Suitable lifting equipment (crane, suction cup) is required for installing the windshield.	AR67.10-P-1000-04MB
		Window installation repair kit	*BR00.45-Z-1060-02A
24	Prepare windshield (1) for installation		AR67.10-P-1000-03MB
		Repair kit	*BR00.45-Z-1015-02A
		Window installation repair kit	*BR00.45-Z-1060-02A
25	Prepare body flange for installation of window		AR67.10-P-1501-01MB
		Repair kit	*BR00.45-Z-1015-02A
		Window installation repair kit	*BR00.45-Z-1060-02A
26	Insert and align windshield (1).	Suitable lifting equipment (crane, suction cup) is required for installing the windshield.
27	Heat butyl string.	Connect copper wires (arrows) to 12 V energy source Heating time approx. 5 minutes.
28	Apply glue	The curing time is approx. 1 hour.	AR67.10-P-1000-08MB
		Betagun 2K electric cartridge gun	*WH58.30-Z-1002-20A
		Repair kit	*BR00.45-Z-1015-02A
29	Check gap between armor plate on inner side of A-pillar and windshield (1).	If gap is larger than 3 to 4 mm: ↓ Glue in splinter guard. Fill gap approximately half full with Beta Seal, insert splinter guard and seal again with Beta Seal Splinter guards are not available as replacement parts. Order from MANUFAKTUR in Sindelfingen, Germany.
		Beta Seal adhesive	*BR00.45-Z-1005-02A
30	Install copper wire ends between A-pillar and windshield.	Do not cut off copper wire ends.
31	Install paneling on outside of A-pillar.		AR88.80-P-8500M
32	Install windshield molding		AR67.10-P-1200M
33.1	Install connections for window heater (2, 3) on A-pillar.	Only with heated windshield.
34.1	Install paneling on A-pillar in right footwell	Only for Code (Z04) light armoring with heated windshield.
35	Install splinter guard on A-pillar.	Splinter guard should not make direct contact to windshield, otherwise windshield can be damaged. Shim splinter guard with washers
			*BA63.20-P-1001-01A
36	Install bracket for paneling on A-pillar.		*BA63.20-P-1002-01A
37	Install lining on A-pillar		AR68.30-P-4050MC
38	Install sun visors
39	Install overhead control panel control module.		AR82.20-P-1000M
40	Install font grab handles.	Observe washers.
41	Install water deflector
42	Install wiper arms		AR82.30-P-6100M
43	Install daylight sensor		AR82.10-P-2400I
44	Clean windshield (1).

PILLARS