Remove/install windshield - AR67.10-P-1700LFS

MODEL 222

with CODE Z07 (Top protection)

Fig 1: Windshield Remove/Install Components (1 Of 4)

Courtesy of MERCEDES-BENZ USA

Fig 2: Windshield Remove/Install Components (2 Of 4)

Courtesy of MERCEDES-BENZ USA

Fig 3: Windshield Remove/Install Components (3 Of 4)

Courtesy of MERCEDES-BENZ USA

Fig 4: Windshield Remove/Install Components (4 Of 4)

Courtesy of MERCEDES-BENZ USA

	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 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
	Notes on removal/installation of windshield		AH67.10-P-1000-01P
	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 (Top protection) with code Z11 (Left front power window with special protection) The side window of the driver door should remain open during the curing time. Otherwise the windshield (1) can be pressed toward outside by the air when the doors are closed. A cloth in the opening of the side window ensures that dirt cannot penetrate through in the inside of the windshield (1).
1.2	Open left or right rear door	Model 222 with code Z07 (Top protection) except code Z11 (Left front power window with special protection) The left and right rear door must remain open during the curing time. Otherwise the windshield (1) can be pressed toward outside by the air when the doors are closed.
2	Remove left and right drip rail		AR88.80-P-4000LF
3	Mask body parts adjacent to windshield (1)	Adhesive tape, air reservoir tensioning strap	*BR00.45-Z-1113-02A
4	Remove detachable parts in area of windshield (1)		AR67.10-P-1050LF
5	Remove inside rearview mirror		AR68.40-P-0001LF
6	Lower headliner and completely push toward rear		AR68.30-P-4300LF
7	Secure electrical wiring harnesses (7) on roof with duct tape
8	Cover dashboard
9	Remove windowbag in area of windshield		AR91.60-P-0693LF
10	Remove upper splinter guard (2) from windshield (1)	Observe number and position of washers.
11	Remove side splinter guard plates (4) from windshield (1)
12	Measure gap dimension between windshield (1) and roof edge and note values	The new windshield (1) can be aligned in the body flange by using the determined gap dimensions. Feeler gauge	Fig 5
13	Measure gap dimension between windshield (1) and left A-pillar and right A-pillar and note values	The new windshield (1) can be aligned in the body flange by using the determined gap dimensions. Feeler gauge	Fig 5
14	Measure height between windshield (1) and left and right A-pillar edge C₁ , C₂ , D₁ and D₂ and note value	The new windshield (1) can be aligned in the body flange using the determined heights C₁ , C₂ , D₁ and D₂ .
15	Cut body sealant (B) at top and both sides	Use commercially available oscillating saw as tool.
16	Open engine hood half way and secure against closing and further opening
17	Mask A-pillar in connection area of heating wires (6) with duct tape
18	Expose heating wires (6) and grind down to bare metal at both ends	In lower area of A-pillar.
19	Fasten suitable lifting device on windshield (1)	Removal: To remove windshield (1) suitable lifting device (crane, cup suction tool) and helper required.
20	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 pulsed power supply unit as power source. Removal: The heating time is approx. 15 minutes. The windshield (1) must heat noticeably. Formation of smoke required.
21	Lift top part of windshield (1) from body first, then pull up and out	Helper required.
22	Cut remaining adhesive
	Install
23	Prepare adhesive cartridge		AR67.10-P-1000-07LFS
		Repair kit for installing windshields, 1-component adhesive	*BR00.45-Z-1135-02A
24	Remove remaining glue from body and windshield (1)	Leave all rubber spacers on body flange.
	Measure
25	Measure resistance of windshield heater in old or new windshield (1)	If the measurement results are outside the tolerance range of 1.9 to 2.3 Ω. ↓ Replace old or new windshield (1)
	Install
26	Insert and align windshield (1) as a trial installation	Use previously determined gap dimensions and height as reference values. Use suitable lifting equipment (crane, vacuum lifter) to insert, align and lift windshield (1). Helper required!	AR67.10-P-1000-09LFS
		Feeler gauge	Fig 5
27	Prepare windshield (1) for installation		AR67.10-P-1000-03LFS
		Sika activator	*BR00.45-Z-1090-02A
		SIKA primer 209, 250 ml	*BR00.45-Z-1104-02A
		Primer	*BR00.45-Z-1171-02A
		Cleaner	*BR00.45-Z-1025-04A
28	Prepare body flange for installation of window		AR67.10-P-1501-01LFS
	General notes about painting the body flange in the glazing area		AH98.00-P-9408-06A
		Repair kit for installing windshields, 1-component adhesive	*BR00.45-Z-1135-02A
		White adhesive tape	*BR00.45-Z-1107-02A
		Cleaner	*BR00.45-Z-1025-04A
		SIKA primer 209, 250 ml	*BR00.45-Z-1104-02A
		Polyester fabric adhesive tape, width 19 mm/length 25 m	*BR00.45-Z-1165-02A
		Support 20x4 mm, windshield glazing	*BR00.45-Z-1166-02A
		Butyl glazing with Cu core 7.5 mm	*BR00.45-Z-1169-02A
		Primer stick	*BR00.45-Z-1012-07A
		Hepox 2K EP primer filler 4017 (Spray Max)	*BR00.45-Z-1050-07A
29	Insert windshield (1) and align on adhesive strips	The windshield (1) must be free of dust and grease. Otherwise adhesion problems can occur between the windshield (1) and the lifting device. Use suitable lifting equipment (crane, vacuum lifter) to insert, align and lift windshield (1). Helper required!
30	Secure windshield (1) against falling down	Adhesive tape, air reservoir tensioning strap	*BR00.45-Z-1113-02A
31	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 pulsed power supply unit as power source.
		The heating duration is approx. 5 minutes, if necessary correct position of windshield (1).
32	Apply sealant (B) between windshield (1) and body flange		AR67.10-P-1000-08LFS
		The curing time is approx. 1 hour. Adhesive, Sikaflex 250 DM6	*BR00.45-Z-1170-02A
33	Install side splinter guard (4) and upper splinter guard (2)	Observe number and position of washers. Do not tighten bolts with torque.
34	Check gap between side splinter guard (4), top splinter guard (2) and windshield (1), if necessary install washers	The side splinter guard (4) and upper splinter guard (2) should not lay directly on the windshield (1). Otherwise the easily scratched coating on the windshield (1) can be damaged.
35	Lay ends of heating wires (6) between A-pillar and windshield (1)	Do not cut off heating wires (6).
36	Cover ends of heating wires (6) with adhesive strips
37	Install left and right drip rail		AR88.80-P-4000LF
38	Tighten bolts on side splinter guard (4)	The adhesive and butyl cord must be sufficiently cured before the side splinter guard plates (4) can be installed. Otherwise the splinter guard plates (4) can stick. Bolt, A-pillar guard plate, windshield to body shell	*BA63.20-P-1004-01D
39	Tighten bolts on upper splinter guard plate (2)	The adhesive and butyl cord must be sufficiently cured before the upper splinter guard plate (2) can be installed. Otherwise the upper splinter guard (2) can stick. Bolt, roof frame guard plate to body shell	*BA63.20-P-1001-01D
40	Fasten windowbag in area of windshield		AR91.60-P-0693LF
41	Install headliner		AR68.30-P-4300LF
42	Install inside rearview mirror		AR68.40-P-0001LF
43	Install detachable parts in area of windshield (1)		AR67.10-P-1050LF
	Check
44	Check all electrical consumers in area repaired for proper function
45	Calibrate mono multifunction camera and stereo multifunction camera		AR54.21-P-3000LF

COLUMNS

Number	Designation		MODEL 222 with CODE Z07
BA63.20-P-1001-01D	Bolt, roof frame guard plate to body shell	Nm	28

COLUMNS

Number	Designation			MODEL 222 with CODE Z07
BA63.20-P-1004-01D	Bolt, A-pillar guard plate, windshield to body shell	M6	Nm	8
BA63.20-P-1004-01D	Bolt, A-pillar guard plate, windshield to body shell	M8	Nm	28

Fig 5: Identifying Feeler Gauge (129 589 03 21 00)

Courtesy of MERCEDES-BENZ USA

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1012-07A	Primer stick	A 000 986 27 50
BR00.45-Z-1025-04A	Cleaner	A 005 989 19 71
BR00.45-Z-1050-07A	Hepox 2K EP primer filler 4017 (Spray Max)	Spies Hecker Gmbh
BR00.45-Z-1090-02A	Sika activator	A 009 989 01 71 14
BR00.45-Z-1104-02A	SIKA primer 209, 250 ml	A 009 989 75 71 09
BR00.45-Z-1107-02A	White adhesive tape	A 006 989 09 85
BR00.45-Z-1113-02A	Adhesive tape, air reservoir tensioning strap	A 655 989 04 85
BR00.45-Z-1135-02A	Repair kit for installing windshields, 1-component adhesive	A 221 670 81 01
BR00.45-Z-1165-02A	Polyester fabric adhesive tape, width 19 mm/length 25 m	A 007 989 07 85
BR00.45-Z-1166-02A	Support 20x4 mm, windshield glazing	A 000 671 00 00
BR00.45-Z-1169-02A	Butyl glazing with Cu core 7.5 mm	A 220 670 02 93
BR00.45-Z-1170-02A	Adhesive, Sikaflex 250 DM6	A 011 989 70 71
BR00.45-Z-1171-02A	Primer	A 005 989 59 71