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

MODEL 166 with CODE Z04 (Light armoring) 

MODEL 166 with CODE Z05 (B5 armoring on special protection version) 

Fig 1: Identifying Windshield Remove/Install Components

	Risk of injury  from cutting wire tearing or becoming hot and from splinters of glass when cutting out bonded windows	Wear protective gloves and safety glasses.	AS67.00-Z-0004-01A
	Risk of injury  from pinching or crushing hands and feet when working on windows.	Secure the windshields and windows against falling down; use only specified lifting tools; wear safety shoes.	AS67.00-Z-0003-01A
	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
	Notes on avoiding damage to windows installed in special high-security vehicles		AH67.00-P-0003-01FB
	Remove
1	Cover dashboard, center console and front seats with suitable protective foil
2	Determine distance between top edge of windshield and front edge of roof and note	If old windshield (1) is still present on vehicle. These dimensions are required for installation.
3	1KPrepare - component adhesive cartridge		AR67.10-P-1000-12SX
		2 adhesive cartridges are required.
		Repair kit, installing windshields, 1-component adhesive Cartridge gun, electric, and preheater gotis://K_67.0_02.  0	*BR00.45-Z-1135-02A
4	Open driver-side window	Leave driver door side window open until adhesive has cured (hardening time). This prevents the windshield (1) from being pressed outwards by the sudden air pressure when the doors are closed.
5	Remove paneling from left and right A-pillars		AR68.30-P-4050WX
6	Remove inside rearview mirror		AR68.40-P-0001GQ
7	Remove rain/light sensor	MODEL 166 with CODE 345 (Windscreen wiper with rain sensor) with CODE Z04 (Light armoring) MODEL 166 with CODE 345 (Windscreen wiper with rain sensor) with CODE Z05 (B5 armoring on special protection version)
			AR82.30-P-7800CW
8	Remove air-water duct		AR83.25-P-1402GQ
9	Remove A-pillar paneling at bottom right	MODEL 166 with CODE Z04 (Light armoring) with CODE Z17 (Heated windscreen) MODEL 166 with CODE Z05 (B5 armoring on special protection version) with CODE Z17 (Heated windscreen)
10	Loosen floor covering on front passenger footwell until electrical connectors are accessible	MODEL 166 with CODE Z04 (Light armoring) with CODE Z17 (Heated windscreen) MODEL 166 with CODE Z05 (B5 armoring on special protection version) with CODE Z17 (Heated windscreen)
11	Disconnect electrical connector from heated windshield (X926)	MODEL 166 with CODE Z04 (Light armoring) with CODE Z17 (Heated windscreen) MODEL 166 with CODE Z05 (B5 armoring on special protection version) with CODE Z17 (Heated windscreen) Fasten electrical connector for heated windshield (X92/6) to windshield with adhesive tape. To prevent damaging electrical line when cutting out.
12	Fasten cord to end of line and pull wiring harness out upward	MODEL 166 with CODE Z04 (Light armoring) with CODE Z17 (Heated windscreen) MODEL 166 with CODE Z05 (B5 armoring on special protection version) with CODE Z17 (Heated windscreen)
13.1	Expose ends of aramid cord at bottom left	Only if aramid cord is present.
13.2	Expose first and second right and left bottom aramid cord on windshield (1)	If two aramid cords are present. When removing the windshield, first pull red aramid cord from one side to the other. Then pull out yellow marked cord.
14	Cut out windshield (1) and lift from body flange with crane and suction lifting device	Helper required to guide windshield (1). Otherwise adjacent body parts can be damaged. Pull aramid cord marked in yellow over the unmarked aramid cord toward left in direction of travel; then pull unmarked aramid cord toward right below the other aramid cord. Any other procedure can result in the aramid cords crossing and tearing during removal. Wet and dry vacuum cleaner gotis://P_00.12_06.  0
	Install
	General notes about painting the body flange in the glazing area		AH98.00-P-9408-06A
15	Prepare body flange for installation of window		AR67.10-P-1501-01RT
		Wear cotton gloves. Ensure that no fingerprints are present in the area of the bonding surface. The bonding surface should be free of dust, oil, grease, wax and other adhesive components or dirt residues. Prevents adhesion problems when installing window.
		Cleaner	*BR00.45-Z-1025-04A
		White adhesive tape	*BR00.45-Z-1107-02A
		Bonding agent Sika-Primer 206 G+P	*BR00.45-Z-1019-02A
		Primer stick	*BR00.45-Z-1012-07A
		Hepox 2K EP primer filler 4017 (Spray Max) Wet and dry vacuum cleaner gotis://P_00.12_06.  0	*BR00.45-Z-1050-07A
16	Align windshield (1) in body opening with suction lifting device	If old windshield (1) is no longer present on vehicle. Position and center windshield (1) in body opening with aid of helper, so that distance between top edge of windshield and front edge of roof can be determined and noted. Install adhesive strips as centering aid, cut adhesive strips along top edge of windshield and remove windshield (1). Cup suction tool/suspension equipment (for window removal/installation) gotis://K_67.0_03.  0
		Feeler gauge	Fig 2
17	Prepare windshield (1) for installation		AR67.10-P-1501-02GQS
		Wear cotton gloves. Ensure that no fingerprints are present in the area of the bonding surface. The bonding surface should be free of dust, oil, grease, wax and other adhesive components or dirt residues. Prevents adhesion problems when installing window. Replace windshield rubber spacers.
		Repair kit, installing windshields, 1-component adhesive Cup suction tool/suspension equipment (for window removal/installation) gotis://K_67.0_03.  0	*BR00.45-Z-1135-02A
18	Apply adhesive material		AR67.10-P-1000-08SX
		Wear cotton gloves. Ensure that no fingerprints are present in the area of the bonding surface.
		Repair kit, installing windshields, 1-component adhesive	*BR00.45-Z-1135-02A
		Adapter	Fig 3
19	Install windshield (1)		AR67.10-P-1503-01GQS
		Install windshield (1) within 5 minutes after applying adhesive material on body side to adhesive bead. Otherwise adhesive force of adhesive starts to decrease.
20	Allow adhesive to dry	After installing the windshield (1) if possible do not open or close the doors while the adhesive is curing. Momentary pressure in the vehicle interior can lift the windshield (1) or have a negative effect on the adhesive bond (if one of the door windows has not been opened previously. After installing windshield (1) do not move vehicle until adhesive has dried. Observe the drying time specified by the adhesive manufacturer. This ensures sufficient strength of the adhesive.
21	Remove fabric adhesive tape, covering material and masking tape from vehicle	Clean repair area if necessary.
22	Install air/water duct		AR83.25-P-1402GQ
23	Install rain/light sensor	MODEL 166 with CODE 345 (Windscreen wiper with rain sensor) with CODE Z04 (Light armoring) MODEL 166 with CODE 345 (Windscreen wiper with rain sensor) with CODE Z05 (B5 armoring on special protection version)
			AR82.30-P-7800CW
		Install rain/light sensor only when adhesive is completely dry.
24	Install inside rearview mirror		AR68.40-P-0001GQ
25	Install cover on left and right A-pillars		AR68.30-P-4050WX
26	Install water deflector on left and right		AR88.85-P-2100RT
27	Check all electrical consumers in area repaired for proper function

Fig 2: Identifying Feeler Gauge (129 589 03 21 00)

Fig 3: Identifying Adapter (000 589 86 63 00)