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Removal/refitting of servo pump pulley
The procedure is the same for all pump variants.
1 Remove the pulley from the pump shaft
using puller 89 96 423.
2 Refit the pulley onto the pump shaft using
tool 89 96 415.
$ 7113
Page 43
To change the glued wind-
screen
The windscreen is glued to the flange in the
windscreen opening. This improves the strength
and rigidity of the body.
A special polyurethane adhesive is used for glue-
ing the windscreen. For strength reasons, this
must not be replaced by any other type of glue or
by tape.
Spacers for fitting the windscreen in position are
taped to every new windscreen supplied.
The external decorative strip is produced in the
form of aring. It is held in position by means of a
plastic retaining strip secured to the edge of the
windscreen.
Materials
Adhesive, cleaning agent and primer are avail-
able as spares (spares type 45) in kits that are
sufficient for one windscreen.
Note
Only the adhesive, cleaning agent and primer
supplied as genuine spares have been tested
and approved.
To change the windscreen
The space between the edge of the windscreen
and the body is covered by a decorative strip
which is kept in position by a strip retainer.
The decorative strip and its retainer must first be
removed before the adhesive can be cut to re-
move the windscreen.
1 Windscreen
2 Strip retainer
3 Decorative strip
4 Adhesive
5 Body flange
6 Spacer
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To remove the windscreen
1 Use a screwdriver to remove the strip re-
tainer joint pieces in the bottom corners.
2 Remove the decorative strip.
3 Tape the edges all round to avoid damaging
the paintwork.
4 Lift out and remove the strip retainer.
5 Cut away the windscreen.
e Start with a 24 mm long knife.
¢ Start the machine and insert the knife through
the bead of adhesive.
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@ Move the machine clockwise and cut away the
adhesive all round.
If the windscreen is not released, it may be
necessary to cut again, using the 36 mm long
knife.
6 Fit the lifting handles and remove the
windscreen. Note the locations of the hand-
les.
7 Remove the protective tape from the body.
Preparations for fitting the windscreen
1 Fit the lifting handles to the outside of the
windscreen and place it on a stand, with the
inside up.
2 Cut down the bead of adhesive on the
windscreen flange and on the windscreen (if
it is to be refitted) to a maximum height of 2
mm, using the trimming knife.
ssew \
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Note
Old adhesive which adheres firmly provides a
good anchor for the new bead of adhesive. Any
loose adhesive on the paintwork and windscreen
must be removed. Wash the surface with clean-
ing agent and apply the primer.
3 Touch up any paintwork damage that will be
concealed by the decorative strip.
Note
To prevent rusting, it is very important that the
paintwork should be in good condition.
To fit the windscreen
The car must be standing on its wheels on a level
surface when the windscreen is being fitted.
Note that only the adhesive, primer and cleaning
agent in the genuine spares kit has been tested
and approved for fitting the windscreen.
Good adhesion is conditional on the surfaces
being thoroughly clean (degreased) and pre-
treated with primer (which promotes adhesion).
See also under "Sheet metal and paintwork re-
pairs”.
The description below is based on the assump-
tion that a new windscreen is being fitted and
that the flange in the windscreen opening has
been repainted. Carry out the appropriate opera-
tions described under the heading "Preparations
for fitting the windscreen”.
1 Place the spacer pieces at the bottom of the
windscreen opening.
S$ 8644
Page 47
2 Carefully wash the edge of the windscreen
and the flange in the opening with cleaning
agent. Wet the surface thoroughly with a
piece of cloth and then wipe it dry with
another piece of cloth.
Note
Fatty residues will remain if the cleaning agent is
allowed to dry naturally. Always use clean, lint-
free cloth. Turn the cloth frequently and take a
new piece of cloth for every object.
3 Apply primer to the edge of the windscreen
and the flange in the windscreen opening.
See the description in item 5.
4 Fitthe strip retainer.
Note
The decorative strip can be fitted with the
windscreen in position, but it is an advantage to
be able to adjust the height of the windscreen by
means of the strip.
Note
Press the strip into place (don't use a mallet to
hammer it into place) so that the sealing com-
pound in the strip will seal correctly.
S 8/646
S 9/645
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5 Use the nozzle to apply a bead of adhesive to
the windscreen. Adjust the pressure on the
applicator so that the bead of adhesive will
have the correct shape.
Note
The width of the applicator nozzle must be ad-
justed. Heat the nozzle in hot water and com-
press the tip.
e Hold the nozzle at right angles to the wind-
screen and apply the bead of adhesive along
the edge of the strip retainer.
Check that there are no gaps in the bead of
adhesive.
11mm
S 8/647
iqg6-7mm
S$ 8/455
S 8648
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6 Fit the windscreen into place and check that
the decorative strip is correctly in position.
Press down the windscreen so that the de-
corative strip is in contact with the body all
round.
Hardening and leakage testing
Hardening is accelerated by moisture and heat.
Tightness testing can therefore be carried out
immediatley after fitting. It is advantageous if
fitting of the windscreen is planned so that the
car can be left undisturbed overnight. The ad-
hesive will then have a longer time to harden,
which is particularly important in the winter.
$86
The car can be moved after about two hours.
Tightness testing and sealing of any
leakage
4 Raise the decorative strip slightly at the
centre of the top edge and pour in some
water.
2 Check from the inside of the car that no
water leaks in.
3 .Seal any leakage from the inside.
e Benda tipped standard nozzle.
e Inject the adhesive and smooth it out with a
piece of wood (dip the piece of wood in soapy
water, so that the adhesive will not stick to it). _———S
Cleaning
Petrol (gasoline) is recommended for removing
residues of adhesive.
S 8/650
Note
Take care when cleaning the inside of the
windscreen, so that you will not disturb it before
the adhesive has set.
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Sedan
Four-door
a Free the safety padding from the windshield
pillars and fold it out of the way.
b Remove the moulding from the rear window
sealing strip.
c Tape the sealing strip to the roof to prevent
its falling out of the window frame when the
window is removed.
d Disconnect the heating element cables for
the rear window.
e Remove the rear window.
f Slide the headlining forward slightly, to free
it from the corner pieces at the back.
g Withdraw the headlining through the rear-
window aperture.
On the two-door Sedan, the headlining can be re-
moved through the right-hand door, provided
that a certain amount of care is taken.
Refit in the reverse order.