Windshield: Service and Repair
Windscreen
To remove
1. Open the door windows to prevent them from breaking due to the pressure that builds up in the cabin if any of the doors closes rapidly.
2. Remove the wiper arms.
3. Remove both the cover over the bulkhead partition space and the water guard.
4. Turn the eccentric stops to open position.
5. Remove the roof seal from the A-pillars on both sides.
6. Remove the decor on the outside of the A-pillars by:
6.a. Pull out the plastic pins.
6.b. Carefully bending the plastic clips loose using 82 93 474 Removal tool. Take care not to damage paintwork or seals.
7. Remove the upper decor strip. If necessary, pull off the retainer strip with a pair of pliers.
8. Remove the A-pillar trim.
9. When replacing glued window panes, use 82 93 714 Kit, window removal tool. If the glass is so damaged that suction cups do not adhere, use 30 14 099 Cutting wire handle to saw out the pane with the help of a colleague.
WARNING: Use the protective equipment that is supplied with the windscreen removal and adhesive kit, such as the goggles and protective gloves.
10. Measure out 6.5 m of cutting wire.
11. Insert the screwdriver through the adhesive joint from the inside of the window in the centre of the window's bottom edge.
12. Hook the ends of the wire into the eye of the screwdriver and bend over the ends so they will not slide off.
13. Pull the screwdriver back through the adhesive into the cabin. Pull in the wires about 0.7 m.
14.
WARNING: Ensure that the wire is not connected to the battery terminals if the cover is removed, otherwise there is a risk of short-circuit/fire.
Unhook the cutting wire from the screwdriver. Straighten the ends of the wire to an oblique angle. Remove the screwdriver from the car.
15. Position the cutting wire around the windscreen. Make sure it lies around all corners. Pull in the wires and check the position of the wires.
NOTE:
- In certain cases, the adhesive may be positioned so low that there is no metal edge to place the cutting wire against (it then glides under the metal edge and cannot cut through the adhesive). If this is the case, make four holders to keep the wire in place against the adhesive.
- Press the holders into the adhesive and place the wire in the holders. Then pull the wire into the car and continue as follows:
16. Fit the reels on the corners inside the window.
17. Fasten the ends of the wire in the reel spools. Make sure the wires do not get crossed. Use the groove in the reel suction cup as a pulley to obtain a good angle.
18. Press the plastic guard down between the cutting wire and the panel to protect the interior.
19. Wind with a ratchet handle so that the wire cuts through the adhesive. Move the plastic guard as you cut. Gradually move the reel to obtain a good angle. An acute angle will cut better. If necessary, use the second reel for support. If you think the wire might break, cease cutting for about 10-15 seconds to allow the wire to work into the adhesive.
20. When the wire begins to cut towards the upper part of the window, fit the protective tool with suction cup between the cutting wire and the metal roof to protect the interior. Move the reel and the protective tool as the wire is moved.
21. Fit the lifting handle on the outside of the window.
22. Have a colleague help to lift away the window.
To fit
IMPORTANT: Betaseal X 2500 cures in 1 hour at 23 degrees C and 50% relative humidity. To avoid the glass from coming loose or its position changing during the curing time, the car must not be subjected to jolts or blows. The doors, tailgate and bonnet must not be shut. The car must not be rocked or rolled. Neither must the glass be pressed in while the adhesive is curing.
Use 30 05 600 Adhesive kit when gluing window panes. To avoid confusion when cleaning and priming, the tube caps are different colours.
The car must be standing on all four wheels on a level surface when fitting the window. In order to obtain as good a result as possible, it is essential that all cleaned and primed surfaces are kept free from dirt while work is in progress. The same applies to the adhesive when being applied. Consequently, work must progress without interruption until the window has been fitted and the adhesive hardened. The adhesive will start to harden as soon as the contents of both tubes have been mixed together. The window must then be in place within 5 minutes from when the adhesive was first applied. Note that points 7-10 must be carried out in exactly the given order so that a satisfactory result is obtained with maximum adhesion.
1. Cut down the adhesive joint on the window flange to a height of max 2 mm. Use the cutting tool contained in the removal kit. If the old window is to be refitted, the adhesive joint on the window should also be cut down to max 2 mm. Old, well adhering adhesive forms a solid bond with the new adhesive bead. Loose adhesive on glass or metal is to be removed.
2. Remove loose particles and dirt from the metal flange with a vacuum cleaner.
3. Repair any damage to the paintwork.
- Scrape off any loose flakes of paint with a knife.
- Clean with Teroson Cleaner FL.
- Apply primer. Use Standox 1K Fullprimer.
- Apply the finish coat.
IMPORTANT: The paintwork must be kept intact so that rust does not form. An insufficient repair to paintwork can also lead to layers of paintwork flaking under the adhesive bead.
4. Apply primer (green) on any touched up surfaces. Body primer should not be used on old, well adhering adhesive.
5. Fit the lifting handle on the outside of the windscreen and place it inside up on a stand at a suitable work height.
6. Press the retainer strip together with the decor list on the top edge of the windscreen. The decor list should stick out an equal amount on both sides. Position spacers along the windscreen.
7. Thoroughly clean the window edge with Betaclean 3300. Carefully wipe the edge with the moist cleaning cloth. Dry it with the dry cleaning cloth included in the adhesive kit. Avoid touching the cleaned surface.
IMPORTANT: The cleaning agent will leave remains of grease if allowed to self-dry. Always dry with clean, lint-free rags. Use both sides of the rags often.
8. Apply Betaprime 5061 (green) to the cleaned surface. In the lower edge of the window, primer should be applied at a width of 20 mm directly above the dotted line. Allow the primer to dry for 10 minutes. Use the glass primer included in the adhesive kit.
9. Apply the adhesive as follows:
- Cut off the tip of the glue cartridge nozzle to obtain a suitable shape.
- Adjust the pressure of the glue gun.
- Hold the gun at right angles to the window. Starting at the lower edge of the window, apply a bead of adhesive to the primed surface and along the retainer strip. Make sure that there are no breaks in the adhesive bead.
IMPORTANT: The adhesive starts to cure as soon as the contents of the two tubes is mixed. Fit the window glass within 5 minutes of starting to apply the bead of adhesive.
10. Have a colleague help to lift the window into place.
10.a. Adjust the window up towards the roof. Check that there is the same distance towards the A-pillars on the right and left side. Press in the window towards the spacers.
10.b. Secure the windscreen in this position and turn up the eccentric stops so that they are positioned against the windscreen.
11. Lift up the top edge of the decor strip somewhat in the middle and pour water. Check to make sure that water does not leak into the cabin.
12. Reset the glue gun.
13. Refit the decor strip on the outside of the A-pillars. Start from the top and guide it in correctly using the upper retainer strip clips.
14. Allow the adhesive to harden before continuing to work. Betaseal X 2500 hardens in 1 hour at 23 degrees C and 50% relative humidity.
15. Fit the A-pillar trim.
16. Fit the A-pillar roof seal.
17. Fit the water guard and the cover over the bulkhead partition space.
18. Fit the windscreen wipers. Check their function and park position as well as the windscreen washer system.
19. Clean the windscreen both inside and out.