Remove/Install Rear Window - AR67.20-P-5145LFS

Model 222 

with code Z07 (B7 armoring on special protection version) 

Courtesy of MERCEDES-BENZ USA

Courtesy of MERCEDES-BENZ USA

Courtesy of MERCEDES-BENZ USA

	Risk of injury  caused by slipping when inserting blade in the multicutter and byglass 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  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  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
Notice	Notes on remove/install rear window		AH67.20-P-2000-01T
Notice	Notes on avoiding damage to windows installed in special high-security vehicles		AH67.00-P-0003-01FB
	Remove
1.1	Partially lower side window in driver door and cover opening with clean cloth	Model 222 with code Z07 (B7 armoring on special protection version) with code Z11 (Left front power window with special protection) Side window of driver door must remain open during curing time. An accumulation of air may otherwise arise when a door is closed that presses the rear window (1) outwards. A cloth in the side window opening prevents dirt ingress to inside of rear window (1).
1.2	Open driver door or passenger door	Model 222 with code Z07 (B7 armoring on special protection version) except code Z11 (Left front power window with special protection) Driver door or front passenger door must remain open during curing time. An accumulation of air may otherwise arise when a door is closed that presses the rear window (1) outwards.
2	Mask off adjacent body panels on rear window (1)	Adhesive tape, air reservoir tensioning strap	*BR00.45-Z-1113-02A
3	Protect liftgate in area of rear window (1) against scratches with suitable adhesive tape
4	Remove detachable parts in area of rear window (1)		AR67.20-P-2100LF
5	Remove rear shelf		AR68.30-P-4580LF
6.1	Lower headliner and completely push toward front	Model 222.1 with code Z07 (B7 armoring on special protection version)
			AR68.30-P-4300LFN
6.2	Lower rear section of roof lining and push fully forward	Model 222.9 with code Z07 (B7 armoring on special protection version)
			AR68.30-P-4307LFS
7	Remove roller sun blind for rear window (1)	Model 222.1 with code P09 (Sun protection package) with code Z07 (B7 armoring on special protection version) Model 222.9 with code Z07 (B7 armoring on special protection version)
8	Remove upper splinter guard (2) from rear window (1)	Observe number and position of washers.
9	Remove lower splinter guards (3) from rear window (1)
10	Remove side splinter guards (4) from rear window (1)
11	Cut through adhesive sealant (B) at top and sides with cutter	Ensure that areas of electrical wiring harnesses (5) are not cut. Electrical wiring harnesses (5) may otherwise be damaged and rear window (1) must be replaced. A suitable tool is the commercially available oscillating saw.
12	Unclip cover on left trunk and expose heating wires (6)
13	Cover C-pillar in connection area of heating wires (6) with adhesive tape
14	Grind both ends of heating wires (6) down to bare metal	In lower area of left C-pillar.
15	Secure suitable lifting equipment on rear window (1)	Rear window (1) must be clean and free of grease. Otherwise adhesion problems can occur between the rear window (1) and the lifting device. Suitable lifting equipment (crane, cup suction tools) with a load capacity of min. 150 kg and a helper are required for the removal of rear window (1).
16	Connect heating wires (6) to external power source	Use insulated clamping devices. Otherwise short circuits can occur when coming into the contact with the body. Use a switch-mode power supply unit as the power source. Heating duration is approx. 10 min Heat rear window (1) so that this is noticeably warm. Formation of smoke required.
17	First lift rear window (1) in upper area of body then pull out in upward direction
18	Cut remaining adhesive
	Install
19	Prepare adhesive cartridge		AR67.10-P-1000-07LFS
		Adhesive Betaseal 1751	*BR00.45-Z-1005-02A
20	Remove residual adhesive material from rear window (1)	Where possible, store old rubber spacers as samples for new rubber spacers.
21	Prepare body flange for installation of window		AR67.20-P-5145-08LFS
		Hepox 2K EP primer filler 4017 (Spray Max)	*BR00.45-Z-1050-07A
		Primer stick	*BR00.45-Z-1012-07A
		Glazing repair kit, 2-component adhesive	*BR00.45-Z-1015-02A
		Repair kit for installing windshields, 1-component adhesive	*BR00.45-Z-1135-02A
	Measure
22	Measure resistance of rear window heater on old or new rear window (1)	If the measurement result is outside the tolerance range of 0.46 to 0.53 Ω. ↓ Replace old or new rear window (1).
	Install
23	Insert and align rear window (1) as a trial installation		AR67.20-P-4050-04LFS
		Rear window (1) must be clean and free of grease. Otherwise adhesion problems can occur between the rear window (1) and the lifting device.
		Suitable lifting equipment (crane, cup suction tools) with a load capacity of min. 150 kg and a helper are required for the insertion of rear window (1).
		Rear window glazing repair kit	*BR00.45-Z-1060-02A
		Feeler gauge	Fig 1
24	Prepare rear window (1) for installation		AR67.20-P-5145-03LFS
		Bonding agent Sika-Primer 206 G+P	*BR00.45-Z-1019-02A
		Sika activator	*BR00.45-Z-1090-02A
		Polyester fabric adhesive tape, width 19 mm/length 25 m	*BR00.45-Z-1165-02A
		Cleaner	*BR00.45-Z-1025-04A
25	Insert rear window (1) and align with adhesive tape strips	Rear window (1) must be clean and free of grease. Otherwise adhesion problems can occur between the rear window (1) and the lifting device. Suitable lifting equipment (crane, vacuum hoisting device) with a load capacity of min. 150 kg and a helper are required for the insertion of rear window (1).
26	Secure rear window (1) against slipping off with suitable adhesive tape	Adhesive tape, air reservoir tensioning strap	*BR00.45-Z-1113-02A
27	Connect heating wires (6) to external power source and heat up butyl cord	Use insulated clamping devices. Otherwise short circuits can occur when coming into the contact with the body. Use a switch-mode power supply unit as the power source. Heating duration is approx. 5 min, correct where req., seat of rear window (1).
28	Apply adhesive material between rear window (1) and body flange	Curing time is approx. 1 h.	AR67.20-P-3000-05LFS
		Adhesive Betaseal 1751	*BR00.45-Z-1005-02A
29	Install side splinter guard (4) and upper splinter guard (2)	Screws may not yet be tightened to specified torque.
30	Check gap between side splinter guards (4), upper splinter guard (2) and rear window (1), where req. install washers	Side splinter guards (4) and upper splinter guard (2) may not be in direct contact with rear window (1). The easily scratched coating of rear window (1) may otherwise be damaged. Observe number and position of washers on upper splinter protection plate (2).
31	Tighten bolts on side splinter guard (4)	Adhesive and butyl rope must be sufficiently cured before side splinter guards (4) are installed. Side splinter guards (4) may otherwise stick.
		Bolt, C-pillar guard plate, rear window to body shell	*BA63.20-P-1005-01D
32	Install lower splinter guards (3) on rear window (1)	Bolt, C-pillar guard plate, rear window to body shell	*BA63.20-P-1005-01D
33	Tighten bolts on upper splinter guard plate (2)	Adhesive and butyl rope must be sufficiently cured before upper splinter guard (2) is installed. Otherwise the upper splinter guard (2) can stick.
		Bolt, roof frame guard plate to body shell	*BA63.20-P-1001-01D
34	Remove roller sun blind for rear window (1)
35.1	Install headliner	Model 222.1 with code Z07 (B7 armoring on special protection version)
			AR68.30-P-4300LFN
35.2	Install rear section of roof lining	Model 222.9 with code Z07 (B7 armoring on special protection version)
			AR68.30-P-4307LFS
36	Install rear shelf		AR68.30-P-4580LF
37	Install detachable parts in area of rear window (1)		AR67.20-P-2100LF
38	Lay ends of heating wires (6) between C-pillar and rear window (1)	Do not cut off heating wires (6).
39	Cover ends of heating wires (6) with adhesive strips
40	Clip cover into left trunk
	Check
41	Check all electrical consumers in area repaired for proper function

Fig 1: Identifying Feeler Gauge (129 589 03 21 00)

Courtesy of MERCEDES-BENZ USA