Unbroken Side Window - Removing/Installing

UNBROKEN SIDE WINDOW, REMOVING/INSTALLING

REMOVING

Caution!
Tape off areas of D-pillar and side panel to prevent damage to paint

- Using an awl, push through window adhesive from inside to outside close to base of C-pillar.

- Thread cutting wire through hole from outside to inside.

Fig. 2 - Unbroken Side Window, Removing/installing:

- Position cutting wire outside along C-pillar under PVC coating from bottom to top (arrow -A-).

- Pull cutting wire down along D-pillar between PVC coating and roof molding (arrow -B-).

- Pull cutting wire out at base of D-pillar and then push through in direction of arrow -C- between side panel and glass.

- Using awl, push through adhesive at lower C-pillar and side panel from inside to outside.

Fig. 3 - Unbroken Side Window, Removing/installing:

- From inside, pull cutting wire through hole. Wire routing now follows -1-.

- Attach handles to ends of cutting wire -A- and -B-.

- From inside, pull cutting wire through adhesive until side window is released.

Caution!
The PVC coating must not be damaged in the visible area. Consider a window broken when PVC is damaged in the visible area.


INSTALLING

- Cut adhesive on undamaged side window flat using a carpet knife.

Note:

^ Do not remove all of the adhesive. The remaining adhesive serves as a foundation for the fresh adhesive sealant that needs to be applied.

^ Keep adhesive free of dirt and grease.

Caution!
Do not apply primer and do not use cleaning fluid on the window.

Note:
Use adhesive sealant, Part No. D 009 100 03. If installing more than one window Part No. D 004 300 05 (two component adhesive sealant) may also be used.

Fig. 4a - Unbroken Side Window, Removing/installing:

- Apply adhesive sealant all around glass to center of remaining adhesive.

a = 1/2 in. (12 mm)
b = 5/16 in. (8 mm)

Note:
Reduce the height of the adhesive sealer bead by the thickness of the material remaining on the glass and on the window flange.

Fig. 4b - Unbroken Side Window, Removing/installing:

- Glue on 4 spacers (arrows).

- Install side window glass into opening and insert PVC tab between roof molding and cover.

- Hold window in place with tape.

- Fasten PVC surround to C-pillar with rivets.

- Observe curing times:

3 hours for Part No. D 009 10003
1 hour for Part No. D 004 300 05