Back Window Glass: Service and Repair
Removing And Installing Rear Window
Tools
Technical values
Preliminary work
1. Remove hardtop. Refer to Removing and installing hardtop.
2. Place outer side of hardtop on the assembly fixture.
General warning notes
Refer to General information on installing and removing car windows
Tools and materials
The following tools and materials are required for removing and installing the rear window with 2-component adhesive:
Removing rear window
Preparing the rear window (hardtop) for removal
1. Unscrew fastening screw -1- from the centring journal -2- on the left and right and take off support -2-.
2. Unclip hardtop locking element trim panel -3- on the left and right.
3. Unclip lining -4- at the sides and at the rear from the hardtop body -5-.
4. Pull plastic rail -6- on roof liner -7- to the rear and disengage.
INFORMATION: To avoid damaging the electric line when cutting out the rear window, affix this to the rear window with adhesive tape.
5. Disconnect electrical plug connection -8- at left and right of rear window.
6. Place hardtop on the assembly fixture and lock with the latching levers and the locking lever at front.
INFORMATION: If the cover section is removed undamaged, it can be re-used.
7. Loosen and pull off the cover section -9-.
Removing rear window
INFORMATION:
- When cutting out the rear window, take care not to damage the rivet connections that are connecting the hardtop body parts.
- When cutting out the rear window, make sure to cut close to the rear window.
1. Fit a cutter -C- with a u-type cutter -E-. Set the vibration frequency controller to 5. Cut through the bond between the body and the rear window at the top, bottom and sides. Refer to General information on installing and removing car windows
2. Taking off rear window
Preparing window aperture for installation
Removing adhesive on the hardtop body
INFORMATION: The surface coating of adhesive residue helps new adhesive to stick. Keep cut surfaces clean and free of grease and do not clean with cleaning solution.
1. When removing remaining adhesive -10- with the cutting tool -C- and the flashing knife -D- on the hardtop body, ensure that a surface coating of adhesive remains -2-.
Cleaning and priming paint damage or newly built-up paint areas in the window aperture of the hardtop body
INFORMATION: A ventilation period of at least 10 minutes must be observed between the cleaning of the glass section and the application of the primer. No cleaning solution residues may remain on the body.
1. Clean new paint areas or damage to the top coat paint in the non-visible area of the glass section in the hardtop body with cleaning solution -H1- and patch with primer -H2-.
Preparing rear window for installation
Removing adhesive from the rear window
INFORMATION:
- Only if the rear window is to be re-installed.
- The remaining adhesive helps new adhesive to stick. Keep cut surfaces clean and free of grease and do not clean with cleaning solution.
1. Equip cutter -C- with flashing knife -D- and remove remaining adhesive from the rear window, ensuring that a surface coating of adhesive remains.
Applying activator to the bonding section of the rear window
INFORMATION:
- Only with new rear windows
- Only if the rear window is re-installed
1. During long idle periods apply activator -H3- to the remaining adhesive.
INFORMATION: A ventilation period of at least 10 minutes must be observed between the cleaning of the glass and the application of the primer. No cleaning solution residues may remain on the body.
2. Clean the windscreen with cleaning solution -H1-.
3. Apply primer -H2- to the window flange in the area of the marking.
Fitting cover section
INFORMATION: If the cover section is removed from the rear window undamaged, it can be re-used.
1. Attach cover section -9- to the rear window.
Installing rear window
Preparing 2-component adhesive for processing
INFORMATION:
- The adhesive has an open time of -15 min-, which means that the bonding material must be applied and the car window must be assembled within this period of time.
- In order to ensure that the substance is completely mixed, apply a 30 mm long adhesive bead of fresh adhesive to a piece of cardboard before processing.
1. Preparing 2-component adhesive for processing.
Applying adhesive on the rear window
INFORMATION: When applying the adhesive, it is essential to ensure that the adhesive bead overlaps by approx. 30 mm at the beginning and at the end.
1. Using bonding gun -A- apply 2-component adhesive to the rear window along the seal -3- in the form of a triangular bead with the dimension -X= ca. 15 mm- -Y= ca. 8 mm-.
Inserting rear window into the hardtop body
CAUTION: Danger of material damage if specified curing time of adhesive is not observed.
- There will not be a proper adhesive bond if the prescribed curing time of the adhesive is not observed.
- The vehicle must not be used until the curing time has elapsed.
- Curing time: 3 hours
- Temperature: at least 10°C
- Fixing time: approx. 1 hour
1. Affix suction cups -B- to the rear window.
INFORMATION: Two persons are needed to insert and adjust the rear window.
2. Insert the rear window at the top of the window aperture and lay it down carefully into the aperture.
3. Press the rear window fully upwards, pressing on the lower edge of the glass while doing so. Use adhesive tape to prevent the rear window from slipping at the side and the top.
Completing the rear window (hardtop) after installation
1. Place outer side of the hardtop on the assembly fixture.
2. Connect electrical plug connection -8- at left and right of rear window.
3. Engage roof liner -7- to the rear using plastic rail -6-.
4. Clip in lining -4- at the sides and at the rear on the hardtop body -5-.
5. Clip hardtop locking element trim panel -3- on the left and right.
6. Insert centring journal -2- on the left and right, screw in the fastening screw -1- and using torque. Tightening torque: 7.5 ftlb.
Subsequent work
1. Install hardtop. Refer to Removing and installing hardtop.