648619 Removing and installing rear window
WM 648619 Removing and installing rear window
General warning notes
-> 6400IN IN - General information on installing and removing car windows
Tools and materials
The following tools and materials are required for removing and installing the windscreen with 2-component adhesive:
Removing rear window
Removing rear window (hardtop)
Removing and installing rear window (hardtop)
1. Remove hardtop.
1.1. Unlock hardtop and take it off the car.
2. Position the hardtop.
2.1. Place outer side of the hardtop on the assembly fixture -> 6102IN IN -assembly instructions for hardtop assembly fixture Procedures.
3. Unclip lining.
3.1. Unclip lining -1- at the sides and at the front from the hardtop body -2-.
Unclipping lining
4. Disengage roof liner at rear.
4.1. Pull roof liner -3- backwards and detach it.
Disengaging roof liner at rear
5. Disconnect the plug connection of the rear window heating.
Information
- To avoid damaging the electric line when cutting out the rear window, affix this to the rear window with adhesive tape.
5.1. Disconnect electrical plug connection -4- at left and right of rear window.
Disconnecting the plug connection of the rear window heating
6. Turn hardtop.
6.1. Place hardtop on the assembly fixture and lock with the latching levers and the locking lever at front.
Turning hardtop
7. Pull off cover section.
Information
- If the cover section is removed undamaged, it can be re-used.
7.1. Loosen and pull off the cover section -5-.
Pulling off cover section
8. Remove 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.
8.1. 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.
Removing rear window
9. Take off rear window.
Preparing window frame for installation
Preparing the window section (hardtop) for installation
Removing and installing rear window (hardtop)
1. Remove 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.
- Remove remaining adhesive between the riveted joints as much as possible without damaging the riveted joints.
1.1. When removing remaining adhesive -6- with the cutting tool -C- and the flashing knife -D- on the hardtop body, ensure that a surface coating of adhesive remains -7-.
Removing adhesive on the hardtop body
2. Clean and prime 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.
2.1. 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-.
Removing rear window (hardtop), cleaning and priming the window aperture of the body
Preparing rear window for installation
Preparing the rear window (hardtop) for installation
Removing and installing rear window (hardtop)
Information
- Only if the rear window is re-installed
Information
- Only if the rear window is re-installed!
1. Remove adhesive from the rear window.
Information
- The remaining adhesive helps new adhesive to stick. Keep cut surfaces clean and free of grease and do not clean with cleaning solution.
1.1. Equip cutter -C- with flashing knife -D- and remove remaining adhesive from the rear window, ensuring that a surface coating of adhesive remains.
Removing adhesive from the windscreen
Information
- Only if the rear window is re-installed!
2. Apply activator to the bonding section of the rear window.
Information
- Only with new rear windows
2.1. During long idle periods apply activator to the remaining adhesive.
2.2. Clean glass with cleaning solution.
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.
2.3. Apply primer to the window flange in the area of the marking.
Activating the bonding section of the windscreen
Installing rear window
Installing rear window (hardtop)
Removing and installing rear window (hardtop)
1. Fit the cover section.
Information
- The removed rear window can be reinstalled if there was no prior damage to the rear window and the rear window was removed without damage.
Information
- If the cover section is removed from the rear window undamaged, it can be re-used.
1.1. Attach cover section -8- to the rear window.
Fitting cover section
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.
2. Preparing 2-component adhesive for processing.
3. Apply adhesive to 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.
3.1. Using bonding gun -A- apply 2-component adhesive to the rear window along the cover section in the form of a triangular bead with the dimension -X = approx. 15 mm-.
Applying bonding material to the windscreen
Information
- Two persons are needed to insert and adjust the rear window.
4. Insert rear window into the hardtop body.
4.1. Affix suction cups -B- to the rear window.
4.2. Insert the rear window at the top of the window aperture and lay it down carefully into the aperture.
Installing rear window (hardtop), inserting rear window
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
5. Fix rear window.
5.1. 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.
Fixing rear window
6. Clean the fields of vision.
6.1. Adhesive which has oozed out must be removed immediately and the affected fields of vision must be cleaned using cleaning agent.
7. Turn hardtop.
7.1. Place outer side of the hardtop on the assembly fixture.
8. Plug in rear window heater.
8.1. Connect electrical plug connection -4- at left and right of rear window.
Plugging in rear window heater
9. Engage roof liner to the rear.
9.1. Engage roof liner -3- at rear.
Engaging roof liner to the rear
10. Clip in lining.
10.1. Clip in lining -1- at the sides and at the front on the hardtop body -2-.
Clipping in interior trim parts
11. Install hardtop.
11.1. Place hardtop on the car and lock it.