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Remove/install windshield - AR67.10-P-1000EG

MODEL 212 with CODE (Z04) Light armoring 

Fig 1: Windshield Remove/Install Components
G09977200Courtesy of MERCEDES-BENZ USA
REMOVING Removing     
DANGER 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
DANGER Risk of injury  from pinching or crushing hands and feet when working on windows. Secure windows against dropping; use only specified lifting tools; wear safety shoes.   AS67.00-Z-0003-01A
DANGER Risk of injury  caused by slipping when inserting blade in the multicutter and by glass splinters when cutting out bonded windows Always interrupt air supply when inserting or removing blade.
Wear protective gloves and safety glasses.		   AS67.00-Z-0001-01A
NOTES Notes on avoiding damage to windows installed in special high-security vehicles   AH67.00-P-0003-01FB
NOTES Information on preventing damage to electronic components due to electrostatic discharge   AH54.00-P-0001-01A
1 Cover dashboard, center console and front seats with suitable protective foil    
2 Remove left and right A-pillar paneling    
3 Remove left and right sun visor    
4 Unclip cover from splinter protection plate    
5 Loosen inside rearview mirror and allow electrical lines to hang down    
6 Remove splinter protection plate    
7 Remove multifunction camera On vehicles with code (476) Automatic lane recognition, with code (513) Speed limit assist with code (608) Adaptive highbeam assist. AR54.21-P-3000EW
8 Remove Night View Assist camera On vehicles with code (610) Night View Assist. AR54.30-P-3000SX
9 Disconnect electrical connector from rain/light sensor IMPORTANT When installing a new windshield, remove rain/light sensor and install on new windshield. AR82.30-P-7800CW
10 Remove wiper arms   AR82.30-P-6100CW
11 Remove water collector    
12 Unclip left and right drip rail (4) from rear toward front and remove SPECIAL TOOL Long wedge Fig 8
13 Disconnect electrical connector from heated windshield (X92/6) SPECIAL TOOL Fasten electrical connector for heated windshield (X92/6) to windshield with adhesive tape, to prevent damaging the electrical line when cutting out.  
14 Remove right front door sill molding On vehicles with code (Z17) Heated windshield.  
15 Loosen edge guard in area of lower right A-pillar paneling On vehicles with code (Z17) Heated windshield.  
16 Remove right lower A-pillar paneling On vehicles with code (Z17) Heated windshield.  
17 Loosen floor covering on front passenger footwell until electrical connectors are accessible On vehicles with code (Z17) Heated windshield.  
18 Disconnect electrical connectors for heated windshield and remove contacts from connector On vehicles with code (Z17) Heated windshield. AR00.19-P-0120A
SPECIAL TOOL New passenger vehicle wiring harness repair kit Fig 2
SPECIAL TOOL Wiring harness repair kit, basic Fig 3
SPECIAL TOOL Blade holder with clamping pliers Fig 4
SPECIAL TOOL LSK 8 blade Fig 5
19 Fasten cord to both cable ends and expose wiring harness IMPORTANT On vehicles with code (Z17) Heated windshield, use cord fastened to both ends of cable to route wiring harness when installing.  
20 Mask off left and right A-pillar and front edge of roof in connection area with adhesive tape NOTES Attach adhesive tape to prevent paint damage.  
21 Cover area of water collector with suitable protective film    
22 Cut out windshield (1) and lift from body flange with crane and suction lifting device NOTES Helper required for guiding windshield (1), otherwise, adjacent body parts can be damaged.
IMPORTANT When performing accident repair, check whether it is necessary to install a new windshield (1).
Wet and dry vacuum cleaner
Window glazing device, FSC 1.6
Vacuum lifting device for special protection vehicles, cup suction tool
Cutting blade, Z-shape,
Cutting length 60 mm
Order no.: 6 39 03 081 01 3
Cutting blade, L shape,
Cutting length 25, 4 mm
Order no.: 6 39 03 207 01 2		 AR67.10-P-1000-01TS 
23 Prepare body flange for installation of window NOTES The adhesive areas on the body flange must be absolutely free of dust and grease to prevent a decrease in the gluing force when installing the window. AR67.10-P-1501-01P 
NOTES General notes about painting the body flange in the glazing area Pay attention to notes concerning the preparation of new parts such as the A-pillar, the roof or the side walls.
Wet and dry vacuum cleaner		 AH98.00-P-9408-06A
Repair kit, installing windshields, 1-component adhesive *BR00.45-Z-1135-02A 
Primer stick *BR00.45-Z-1012-07A 
Hepox 2K EP primer filler 4017 (Spray Max) *BR00.45-Z-1050-07A 
24 Remove adhesive tape on A-pillar and front edge of roof    
INSTALLING Install     
25 Measure resistance of wiper heater on new windshield (1) IMPORTANT If the reading is outside of the tolerance range of 1.0 to 1.3 Ω, do not install windshield (1).
Digital multimeter		  
26 Measure resistance of camera heater on new windshield (1) On vehicles with code (476) Automatic lane recognition, with code (513) Speed limit assist, with code (608) Adaptive highbeam assist, with code (610) Night view assist
IMPORTANT If the reading is outside of the tolerance range of 4.5 to 5.5?, do not install windshield (1).
Digital multimeter		  
27 Measure resistance of surface heater on new windshield (1) On vehicles with code (Z17) Heated windshield
IMPORTANT If the reading is outside of the tolerance range of 0.5 to 0.7 Ω, do not install windshield (1).
Digital multimeter		  
28 Prepare glue cartridge   AR67.10-P-1000-12SX 
SPECIAL TOOL Intermediate piece
Cartridge gun
Cartridge preheater (not adjustable)		 Fig 6
Repair kit, installing windshields, 1-component adhesive *BR00.45-Z-1135-02A 
29 Replace rubber window spacer IMPORTANT Do not remove protective foil.  
30 Replace rubber seal on windshield (1) at top IMPORTANT Glue rubber seal to top edge of window at a distance of 6 mm. Position left and right side rubber seal flush on windshield (1).  
31 Align windshield (1) in body opening with suction lifting device NOTES Aid of a helper is required for guiding the windshield (1), otherwise adjacent body parts and the windshield (1) can be damaged.
IMPORTANT The inside of the top apex seal of the windshield (1) should make contact with the front edge of the roof.		 AR67.10-P-1000-04TS 
SPECIAL TOOL Feeler gauge Fig 7
Distance between top edge of windshield and transition between rabbet and front edge of roof
Vacuum lifting device for special protection vehicles, cup suction tool		 *BE67.10-P-1001-01G 
32 Prepare windshield (1) for glazing NOTES The adhesive areas on the windshield must be absolutely free of dust and grease to prevent adhesion problems with the adhesive material when installing the window.
Vacuum lifting device for special protection vehicles, cup suction tool		 AR67.10-P-1000-03TS 
Repair kit, installing windshields, 1-component adhesive *BR00.45-Z-1135-02A 
Cleaner *BR00.45-Z-1025-04A 
White adhesive tape *BR00.45-Z-1107-02A 
33 Apply adhesive material NOTES Install windshield (1) on body flange within 10 minutes after applying adhesive material, otherwise adhesive force of glue starts to decrease.
IMPORTANT Uniformly apply glue in shape of bead at a height of approx. 13 mm.		 AR67.10-P-1000-08P 
SPECIAL TOOL Intermediate piece
Cartridge gun		 Fig 6
Repair kit, installing windshields, 1-component adhesive *BR00.45-Z-1135-02A 
34 Position windshield (1) and align NOTES Ensure that at least one vehicle door remains open while the adhesive material cures. When a vehicle door is closed, the vibration to the body can change the installation position of the windshield (1).
IMPORTANT The inside of the top apex seal of the windshield (1) should make contact with the front edge of the roof.
Vacuum lifting device for special protection vehicles, cup suction tool		 AR67.10-P-1503-01TS 
35 Connect electrical connector for heated windshield (X92/6)    
36 Clip in drip rails (4) IMPORTANT Ensure that drip rails (4) are seated correctly in clips. Ensure that clips are seated correctly in roof paneling.  
37 Install water collector    
38 Install wiper arms   AR82.30-P-6100CW
39 Install multifunction camera On vehicles with code (476) Automatic lane recognition, with code (513) Speed limit assist with code (608) Adaptive highbeam assist. AR54.21-P-3000EW
40 Install night view assist camera On vehicles with code (610) Night View Assist. AR54.30-P-3000SX
41 Fasten electrical connector to rain/light sensor    
42 Install splinter guard plate IMPORTANT Splinter guard plate should make complete contact with windshield (1).  
TORQUE SPECIFICATION *BA63.20-P-1004-01B 
43 Fasten inside rearview mirror    
44 Instal cover for splinter guard plate    
45 Install left and right sun visor    
46 Install left and right A-pillar paneling    
47 Fasten cord to both cable ends and route wiring harness IMPORTANT On vehicles with code (Z17) Heated windshield. Use cord fastened to both ends of cable to route wiring harness when installing.  
48 Install contacts in connector and connect electrical connectors for heated windshield On vehicles with code (Z17) Heated windshield. AR00.19-P-0120A
SPECIAL TOOL New passenger vehicle wiring harness repair kit Fig 2
SPECIAL TOOL Wiring harness repair kit, basic Fig 3
SPECIAL TOOL Blade holder with clamping pliers Fig 4
SPECIAL TOOL LSK 8 blade Fig 5
49 Install floor covering in front passenger footwell On vehicles with code (Z17) Heated windshield.  
50 Install right lower A-pillar paneling On vehicles with code (Z17) Heated windshield.  
51 Fasten edge guard in area of right lower A-pillar paneling On vehicles with code (Z17) Heated windshield.  
52 Install right front door sill On vehicles with code (Z17) Heated windshield.  
53 Remove protective foil on inside of windshield (1)    
54 Remove protective film from dashboard, center console and front seats    
55 Code adaptation of rain sensor and light sensor amplification factor and select type of windshield    
REFER TO SELF-DIAGNOSTIC SYSTEMS Connect STAR DIAGNOSIS and read out fault memory   AD00.00-P-2000-04A
56 Check all electrical consumers in area repaired for proper function.    
TEST AND ADJUSTMENT VALUES FOR WINDSHIELD

Number Designation Model 212
BE67.10-P-1001-01G Distance between top edge of windshield and transition between rabbet and front edge of roof Dimension "a" mm 5 (±1)
- -
COLUMN

Number Designation Model 212 with code Z04
BA63.20-P-1004-01B Nut/bolt, splinter guard to rain/light sensor guard plate Nm 12
Fig 2: Identifying Passenger Vehicle Wiring Harness Repair Kit (220 589 04 99 00)
G09977201Courtesy of MERCEDES-BENZ USA
Fig 3: Identifying Wiring Harness Repair Kit (000 589 13 99 00)
G09977202Courtesy of MERCEDES-BENZ USA
Fig 4: Identifying Blade Holder With Clamping Pliers (220 589 01 99 50)
G09977203Courtesy of MERCEDES-BENZ USA
Fig 5: Identifying LSK 8 Blade (220 589 01 99 56)
G09977204Courtesy of MERCEDES-BENZ USA
Fig 6: Identifying Intermediate Piece (000 589 86 63 00)
G09977205Courtesy of MERCEDES-BENZ USA
Fig 7: Identifying Feeler Gauge (129 589 03 21 00)
G09977206Courtesy of MERCEDES-BENZ USA
Fig 8: Identifying Long Wedge (115 589 03 59 00)
G09977207Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1135-02A Repair kit, installing windshields, 1-component adhesive A 221 670 81 01
BR00.45-Z-1012-07A Primer stick A 000 986 27 50
BR00.45-Z-1050-07A Hepox 2K EP primer filler 4017 (Spray Max) Fritz-Hecker-Str. 47-107
50968 Koln
BR00.45-Z-1107-02A White adhesive tape A 006 989 09 85
BR00.45-Z-1025-04A Cleaner A 005 989 19 71
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