Back Window Glass: Service and Repair

51 31 200 Removing And Installing/Replacing Rear Window

Special tools required:







IMPORTANT:
- The 'Instructions on cementing windscreen" serve as the basis for this repair instruction and must be observed without fail.
- Cover rear side panels with protective covers.

- When reusing the rear window:
- Do not damage plug soldering tags for heated rear window.







Necessary preliminary tasks:
- Remove roofliner for roof shell







NOTE:
Removal is performed with Roll Out 2000.
- Tape off entire roof shell aperture with fabric adhesive tape (paint coat must not be damaged)
- All attachment parts must not be damaged







Move rear roof shell (1) forwards until ... (see next operation)







... frame (1) can be engaged in openings (2) on left and right with a suitable tool.







Disconnect heated rear window plug connections (1) on left and right.

IMPORTANT: Tape off body area at piercing point (1) with fabric adhesive tape (risk of damage).







Push wire starter from Roll Out 2000 at line (1) through adhesive bead.
Cut out rear window with Roll Out 2000.
Lift out rear window with special tool 51 3 010.

Installation:
Bond rear window with hardtop closed.

Fitting 6 spacer buffers:







IMPORTANT:
- To avoid rear window breakage and leaks, remove remnants of removed spacer buffers (1).
- Position new spacer buffers (1) outside adhesive bead.
- Only the following spacer buffers (1) may be used:
- Dia. 9.5 mm and 3.8 mm high







Y1 = applicable to all upper spacer buffers (1)
Y2 = applicable to all lower spacer buffers (1)







Overview of bonding agent application (primer):
Apply bonding agent in marked area (1), but not beyond the ceramic glass screen print.

NOTE: Otherwise wipe again straight away with a fluff-free cloth.







Overview of adhesive bead trace, top and side:
Adhesive bead trace (1) runs inside clinch points (2).

Adhesive bead trace
A = 7(+2) mm (width, adhesive bead trace)
B = 7(+1) mm (height, adhesive bead trace)







Overview of adhesive bead trace, bottom:
Adhesive bead trace (1) runs in sheet recess of cross-member (2).
Spread bead joint (3) with special tool 00 9 322.

Adhesive bead trace
A = 7(+2) mm (width, adhesive bead trace)
B = 7(+1) mm (height, adhesive bead trace)







Attach special tool 51 3 010 twice to tool trolley. Moisten suction surfaces and secure rear window from outside.
If reusing the removed rear window, remove the adhesive residue with a blunt scraper or knife.
Observe treatment of adhesive area in body aperture and on rear window, see Instructions on window cementing

Position and width of bead joint:
- Overlapping and closed
- Not visible from outside and inside
- The contact point becomes noticeable through an increase in the adhesive volume (approx. 1.5 - 2 x bead width after crushing).
Position adhesive bead only where the glass ceramic material offers a sufficient overlap and the body flange offers sufficient space.

- The adhesive bead is not permitted in the window radii and in the cowl panel area







NOTE: Adhesive area for plastic adhesive tapes (1) must be free from grease and dust.

Stick two yellow plastic adhesive tapes (1) to roof at distance (A) from outside corners.
Length: 400 mm
A = 150 mm







Gap dimensions:
A = Centre rear window (2) to roof shell (1) laterally.
B = Rear window (2) to trim strip, soft top compartment lid (3), see Gap dimensions, body.







Checking pre-tension on rear window:
In order to avoid wind noises, rear window (1) must be lower than roof outer skin (2).
Position special tool 51 0 010 in middle of vehicle depending on measurement (A) and check underprotrusion of rear window (1).
A = 2 mm
X = measurement stages 1 ... 4 mm







Installation:
Underprotrusion dimension "A" is decreased by approx. 4 mm continuously from window centre to window edge on left and right.