For 1990-2009 cars

#### Special Tools

• | BO-46974 Glass Removal System

• | BO-641 Suction Holder

For equivalent regional tools, refer to Special Tools.

### Removal Procedure

Warning: Refer to Cracked Window Warning in the Preface section.

Note: Position the vehicle on level ground and move the front wheels to the straight-ahead position.

Warning: Refer to Glass and Sheet Metal Handling Warning in the Preface section.

1. Disconnect battery.
2. Remove air inlet grille panel. Refer to Air Inlet Grille Panel Replacement.
3. Remove windshield garnish molding. Refer to Windshield Garnish Molding Replacement.
4. Remove inside rearview mirror. Refer to Inside Rearview Mirror Replacement.

1. Use BO-46974 system to remove the windshield.

Warning: Refer to Defroster Outlet Warning in the Preface section.

2. Take the diagonal measurement of the windshield.
3. Cut cutting wire into four times lengths.

Tip
ca. 6200 mm, the circumference of the corresponding roll of wire is approximately 1000 mm.

4. Heat the awl with a suitable tool.
5. Stick the awl (1) with adhesive bed in the area of the front wall.

Tip
Ensure that the windshield is not damaged in the process, otherwise stress cracks in the windshield may occur.

6. Pull the wire through.

Tip

• | Thread the cutting wire into the hole of the awl and bend it over.

• | Pull the cutting wire with the awl to the middle of the steering wheel in the interior.

7. Release the roof rail front right and left.
8. Lay the wire under the windshield all the way round.

Tip
The cutting wire (1) should be rolled in beneath the rubber window seal (2) at the windscreen.

9. Pull the second wire end through.

Tip

• | Stick awl approx. 1 cm overlapping the first entry place with adhesive bed.

• | Thread the cutting wire into the hole of the awl and bend it over.

• | Pull the rest of the wire into the interior with the awl.

10. Place the winch with two winding heads (2) in the vehicle.

Tip

• | Position winch in right-hand area of the windshield.

• | Attach the cutting wire to the winch.

• | Insert transfer ratchet and pre-tension cutting wire.

Note: Ensure that the cutting wire is fitted correctly to the winch deflection roller.

11. Cut out windshield.

Tip

• | Use the plastic sheet for the protection of the armature board.

• | Arrow shows the path taken by the cutting wire (1).

• | Cut out the windshield until the cutting wire is level with the winch.

Note: In the area of the A-pillar/front wall, increased cutting effort must be made.

12. Place the winch with two winding heads (2) in the vehicle.

Tip

• | Position the winch near to the interior rear view mirror.

• | Insert transfer ratchet and pre-tension cutting wire.

Note: Ensure that the cutting wire is fitted correctly to the winch deflection roller.

13. Cut out windshield.

Tip

• | Use the hold-down positioner and the plastic sheet to protect the sunroof.

• | Arrow shows the path taken by the cutting wire (1).

• | Cut out the windshield until the cutting wire is level with the winch.

Note: In the area of the A-pillar/roof frame, increased cutting effort must be made.

14. Place the winch with one winding head in the vehicle.

Tip

• | Position the winch with one winding head on the A-pillar on the driver's side (2).

• | Attach the cutting wire (1) to the winch.

• | Insert transfer ratchet and pre-tension cutting wire.

Note: Ensure that the cutting wire is fitted correctly to the winch deflection roller.

15. Cut out windshield.

Tip

• | Arrow shows the path taken by the cutting wire.

• | Cut out the windshield until the cutting wire is level with the winch.

• | Use the plastic sheet for the protection of the armature board.

Note: Use lubricant on the winch deflection roller. More pulling force is required to cut the area around the A-pillar/bulkhead.

16. Place the winch with one winding head in the vehicle.

Tip

• | Position the winch with one winding head in the area of the roof frame (1).

• | Insert transfer ratchet and pre-tension cutting wire (2).

Note: Ensure that the cutting wire is fitted correctly to the winch deflection roller.

17. Cut out windshield.

Tip

• | Arrow shows the path taken by the cutting wire.

• | Cut out the windshield until the cutting wire is level with the winch.

• | Use the plastic sheet for the protection of the ceiling.

Note: Use lubricant on the winch deflection roller. More pulling force is required to cut the area around the A-pillar/roof frame.

18. Position both cutting tools.

Tip

• | Shift winch with two winding heads downwards (1).

• | Shift the winch with one winding head (2) in the ceiling area so that the cutting wire (3) is crossed.

• | Insert transfer ratchet and pre-tension cutting wire.

19. Cut out windshield.

Tip

• | Use the plastic sheet for the protection of the ceiling.

• | Cut out windscreen until the cutting wire has cut through the adhesive bed completely.

• | Arrow shows the path taken by the cutting wire.

20. Remove glass removal system.
21. Fit BO-641 holder .
22. Remove windshield.

Note: Second mechanic required.

23. Cut out the adhesive tape with the knife provided (1) to within 1 mm.
24. Repair any paint damage.

Tip
Using a touch-up pen to match the color of the vehicle, repair any paint damage.

25. Cut off the adhesive bead on the glass pane.

Tip
Cut out the adhesive tape with the knife provided (1) to within 1 mm.

### Installation Procedure

1. Remove all mounds or loose pieces of urethane adhesive from the pinch-weld area.
2. Inspect for any of the following problems in order to help prevent future breakage of the window:

• | High weld

• | Solder spots

• | Hardened sealer

• | Any other obstruction or irregularity in the pinch-weld flange

3. After repairing the opening as indicated, perform the following steps:

Remove all traces of broken glass from the outer cowl panel, seats, floor, and defroster ducts.

4. Apply adhesive bead.

Tip
Cut into the tip of the cartridge in such a way that a bead of adhesive approx. 13 mm thick is produced.

5. Insert windshield.

Tip

• | Place the windshield on the roof frames and lower down.

• | Insert windshield with BO-641 holder .

6. Secure windshield in position with fabric tape.
7. Second mechanic required.
8. Clean any excess urethane adhesive from the body.
9. Use a soft spray of warm water in order to immediately water test the window.
10. Inspect the window for leaks.
11. If any leaks are found, use a plastic paddle in order to apply extra urethane adhesive at the leak point.
12. Retest the window for leaks.
13. Maintain the following conditions in order to properly cure the urethane adhesive:

• | Partially lower a door window in order to prevent pressure buildups when closing doors before the urethane adhesive cures.

• | Do not drive the vehicle until the urethane adhesive is cured. Refer to the above curing times.

• | Do not use compressed air in order to dry the urethane adhesive.

14. Install the roof rail front right and left.
15. Install inside rearview mirror. Refer to Inside Rearview Mirror Replacement.
16. Install windshield garnish molding. Refer to Windshield Garnish Molding Replacement.
17. Install air inlet grille panel. Refer to Air Inlet Grille Panel Replacement.
18. Connect battery.