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Windows (Coupe): Other Smart Fortwo II

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Notes on stone impact repair on laminated glass windows - AH67.10-P-0002-01MCC

Model 450.3/4 except 450.418, 451.3/4, 452.3/4, 454.0

Stone mark repair is only permitted in areas outside the long-range field of vision (2). The long-range field of vision (2) is 29 cm wide and is centered around the center point of the steering wheel on the windshield

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Scheme 20: Notes on stone impact repair on laminated glass windows - AH67.10-P-0002-01MCC
Scheme 20: Notes on stone impact repair on laminated glass windows - AH67.10-P-0002-01MCC

The long-range field of vision (2) is limited at the top and bottom by the windshield wiper field (1).

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Scheme 21

The damage profiles shown here (stone marks on the windshield) can be repaired economically and satisfactorily using the stone mark repair method. A repair set approved by DaimlerChrysler is required for this purpose.

PS laminated glass window repair system

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Scheme 22

Before repairing damage point, please be sure to always observe the following information

  1. A workplace without UV radiation should be available, otherwise it can result in paint adhesion problems of the filler resin or finish resin.
  2. The windshield temperature must be between 10°C and 25°C to repair the stone marks; if applicable, heat or cool down windshield with suitable methods. Otherwise it can result in paint adhesion problems of the filler resin or finish resin.
  3. Only damage on the outside window surface may be repaired.
  4. Damages to the inside of the windshield or to the plastic laminate are not permitted.
  5. Ensure that moisture has not penetrated into the damaged point (seal damage point immediately after damage using adhesive tape and repair it as soon as possible).
  6. The diameter of the chip should not exceeded 5 mm.
  7. Any radial cracks extending from the damage point should not exceed 50 mm. They should not end at the rubber window seal and never reach to the outer edge of the window.
  8. This repair method can be used only when the damaged point is outside the driver's long-range field of vision. After repair, a spot of approx. 2 mm in diameter can still be seen.

Cut out windows with roll out - AR67.10-P-1000-11MCC

NumberDesignationOrder number
BR00.45-Z-1041-02BTS adhesive (with isopropanol cleaner)A 451 989 00 71

REPAIR MATERIALS

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Scheme 23

"Roll out" window removal tool

Scope of supply

Work is shown on windshield

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Scheme 31
  1. Mask off puncture point at position (A) (arrow) from outside with suitable textile adhesive tape and punch from vehicle interior through adhesive seam of window (18) with awl (2).
  2. Cut cutting wire to correct length. The length of the cutting wire should be approx. 4 times the diagonal of the window.
  3. Insert ends of cutting wire (17) through eye of awl (2) and bend over in direction of arrow.
  4. Cover areas adjacent to puncture point in vehicle interior with appropriate interior protection and pull cutting wire (17) approx. 70 cm into passenger compartment using awl (2).
  5. Bend cutting wire (17) straight and remove awl (2).
  6. Moisten sealing lip on window (18) with soapy water. On windows (18) with sealing lip to facilitate inserting cutting wire (17).
  7. Route the remaining outer wire loop between windshield (18) and body flange counterclockwise while pulling the excess cutting wire (17) into the inside of the vehicle. Ensure that cutting wire (17) is located below windshield (18) at all four corner points.
  8. Insert guide needles (5) into adhesive seam at bottom edge of window (18). Only if cutting wire (17) is not attached below window (18). Ensures that cutting wire (17) makes contact to adhesive seam when tensioning.
  9. Install windlass (15) on opposite side of window (18) diagonal of puncture point.
  10. Insert end of cutting wire (17) into coil of windlass (15) with the shorter end toward the windlass (15).
  11. Position reversible ratchet (3) on windlass (15) and tension cutting wire (17). Then check from outside whether the cutting wire (17) makes contact to the adhesive seam on the window all-round. The coil of the windlass (15) can only be turned in one direction, therefore it is necessary to ensure that the cutting wire (17) is located in the guide groove (20) of the windlass (15).
  12. Insert suitable interior protection (10) between cutting wire (17) and inner paneling. Use parabolic chisel (1) at points not easy to reach.
  13. Slowly wrap cutting wire (17) onto coil of windlass (15) and cut out window up to marking (B).
  14. Remove reversible ratchet, parabolic chisel and interior protection and turn windlass (15) to next position. To move windlass (15), release locking knob (19) while retaining under tension the cutting wire (17) of the coil.
  15. Install reversible ratchet, parabolic chisel and appropriate interior protection.
  16. Install windlass (16) on inner side of window.
  17. Install second end of cutting wire (17) in coil of windlass (16).
  18. Install reversible ratchet on windlass (16) and tension cutting wire (17). The windlass coil (16) can only be turned in one direction. Ensure that the cutting wire (17) is located in the guide groove of the windlass (16).
  19. Insert suitable interior protection between cutting wire (17) and inner paneling. Use parabolic chisel at awkward locations.
  20. Slowly wrap cutting wire (17) onto coil of windlass (15) and cut out window up to marking (C).
  21. Slowly wrap cutting wire (17) onto coil of windlass (16) and cut out window up to marking (D).
  22. Move windlass (16) to next position.
  23. Slowly wrap cutting wire (17) onto coil of windlass (16) and cut out window up to marking (E).
  24. Move windlass (15) to next position.
  25. Slowly wrap cutting wire (17) onto coil of windlass (15) and cut out window up to marking (E). Secure window against falling down to prevent damage.
  26. Remove windlasses (15, 16) from window.
  27. Fasten cup suction tool at outside of window and remove window from body flange. Cup suction tool Aid of helper required.

Install windshield - AR67.10-P-1503-01MCC

Shown on model 451.3

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Scheme 32
  1. Center windshield (1) above body opening and position to coincide with strips of adhesive tape (arrows). Cup suction tool Helper required.
  2. Position windshield (1) on body flange and press on until it makes contact with spacers. Then fix in place with suitable adhesive tape. The curing time is approx. 2 h measured from the time the windshield (1) is installed. The rated accident strength is achieved only after approx. 8 h.

Scheme 33

Scheme 33: Prepare repair for windshield - AR67.10-P-1600-01MCC
Scheme 33: Prepare repair for windshield - AR67.10-P-1600-01MCC
  1. Check damaged point for moisture If applicable, heat damaged point with hot air gun and allow to flash off for approx. 10 minutes.
  2. Clean windshield around damaged point with cleaning agent (12).
  3. Evaluate damaged point A conical fissure or filling cavity should be present in each damaged point to ensure that the filler resin (8) continues to flow.
  4. If applicable, crack damaged point to create conical fissure or filling cavity. Use stone impact cracker (5).
  5. Install inspection mirror (3) on inside of windshield.
  6. Chamfer edges of damaged point using milling cutter (4). Roughen surfaces and remove grayness from porous surfaces.
  7. Blow out loose glass particles and wipe out with paper towel. Do not use compressed air when blowing out to prevent enlargement of the damaged point.

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Scheme 34: Repair windshield - AR67.10-P-1600-02MCC
Scheme 34: Repair windshield - AR67.10-P-1600-02MCC

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Scheme 36
  1. Place tool holder (1) on windshield so that it is not in the area of the damaged point.
  2. Press suction cup of tool holder (1) onto windshield with clamping lever (2) in vertical position. To improve adhesion of suction cup moisten with thin layer of adhesion gel (13).
  3. Arrest tool holder (1) on windshield by moving clamping lever (2) down.
  4. Screw injector (10) into tool holder (1) until rubber nozzle (10.1) makes slight contact to windshield.
  5. Mark cracks extending from end of damaged point using suitable pen to check whether cracks have become longer.
  6. Remove tool holder (1) and position so that rubber nozzle (10.1) of injector (10) is located at center of damaged point.
  7. Arrest tool holder (1) on windshield by moving clamping lever (2) down. If the cracks extending from the damaged point increase, immediately reduce pressure by unscrewing injector (10) from tool holder (1) to prevent the windshield from breaking.
  8. Screw injector (10) into tool holder (1) until rubber nozzle (10.1) on injector (10) makes contact with windshield all-round. The contact pressure is indicated in the inspection mirror (3) by the edge of the rubber nozzle (10.1) becoming a darker red or deforming edge (10.1).
  9. Completely unscrew injector piston (10.3), moisten piston thread (10.4) with a drop of filler resin (8) and fill 12 drops of filler resin into the filler opening (10.2). When reusing new injector (10).
  10. Completely unscrew injector piston (10.3) and fill three to five drops of filler resin into filler opening (10.2) When reusing used injector (10).
  11. Provide for sufficient pressure by screwing in injector piston (10.3) (picture B). Observe deformation of rubber nozzle (10.1) of injector (10) to achieve good repair results. The opening is widened (picture B) if sufficient pressure is present. The pressure should not be present more than 90 s.
  12. Hold injector (10) to prevent unscrewing from tool holder (1) and provide for vacuum by unscrewing injector piston (10.3) up to the thread end (picture A). Observe deformation of rubber nozzle (10.1) to achieve good repair results. The opening is smaller (picture A) if sufficient vacuum is present. Do not remove injector piston (10.3) beyond end of thread to ensure that vacuum is maintained. The thread end is indicated by a cracking noise when unscrewing. Maintain vacuum at least as long as pressure. The longer the better.
  13. Increase contact pressure of injector (10) on windshield by screwing injector (10) into tool holder (1). Observe damaged points coming from cracks to prevent additional damage.
  14. Repeat steps 11 to 13 (8 to 12 times). Increase time of pressure 50% for each repetition. The air is completely removed, when air pockets are no longer visible under vacuum after an additional waiting time. Air not completely removed can be recognized as small black spots. Perfect repair does not have black spots. Otherwise, repeat until air pockets are no longer visible.
  15. Check results by holding white background behind. If the repair results are not satisfactory, repeat steps 11 to 15 by maintaining longer pressure and vacuum (2 to 5 minutes) until air pockets are no longer visible.
  16. Cut off an approx. 2 to 3 cm strip of curing foil (11) with bow-shaped blade (7).
  17. Loosen clamping lever (2) and pivot tool holder (1) to side using injector (10). As long as the filler resin (8) is not yet cured, it is possible to continue work at any time.
  18. Slightly wipe out filler resin (8) in damaged point using lint-free cloth.
  19. Apply a drop of filler resin (9) at top of damaged point and attach prepared strip of curing foil (11) first at bottom of mark and lay over area of impact. Avoid formation of air pockets. Do not press curing foil (11) down; this could endanger the repair result. If applicable, repeat operation.
  20. Remove injector (10) from tool holder (1) and screw in injector piston (10.3) one thread.
  21. Store injector (10) in opaque bag to prevent filler resin (8) from curing. Storing filler resin (8) and injector (10) at 4°C to 8°C in a refrigerator prolongs applicability significantly.
  22. Position UV curing lamp (6) above area of impact, switch on and allow filler resin (9) to cure for at least 5 minutes.
  23. Switch on UV curing lamp (6) and remove.

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Scheme 37: Finish windshield repair - AR67.10-P-1600-03MCC
Scheme 37: Finish windshield repair - AR67.10-P-1600-03MCC
  1. Remove curing foil (11).
  2. Scrape off cured finish resin (9) on windshield using bow-shaped blade (7). To achieve good repair results, move bow-shaped blade (7) at an angle of exactly 90° to windshield by weaving crosswise above damaged point. Scraped finish resin (9) is visible as mat or gray surface. Shining resin surfaces are located deeper and not yet sufficiently filled and must be treated with finish resin (9).
  3. Apply a drop of finish resin (14) to scraped finish resin surface and polish to transparent finish using polishing cloth from repair kit. To achieve good repair results, a small quantity of dry finish polish (14) should already be present on the polishing cloth. The final result is a shining transparent point, similar to a dried rain drop.
  4. Clean repair surfaces using cleaning agent (12).

Repair of windshield - AR67.10-P-1600MCC

MODEL 451.3 /4, 454.0

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Scheme 38: Repair of windshield - AR67.10-P-1600MCC
Scheme 38: Repair of windshield - AR67.10-P-1600MCC

Notes on stone impact repair on laminated glass windows AH67.10-P-0002-01MCC The following tools are required for stone impact repair for windshield PS laminated glass window repair system 1 Prepare repair of windshield AR67.10-P-1600-01MCC 2 Repair windshield AR67.10-P-1600-02MCC 3 Finish windshield repair AR67.10-P-1600-03MCC

Risk of injury caused by slipping when inserting blade in the multicutter and by glass splinters when cutting out bonded windows - AS67.00-Z-0001-01A

Always interrupt air supply or power supply before inserting or removing blade.

Wear protective gloves and safety glasses.

Risk of injury

When inserting or removing the blade for the multicutter, body parts may be cut if the tightening wrench slips or if the multicutter switches on unintentionally.

Injuries to eyes and hands may be caused by flying glass splinters when cutting out bonded windows.

Safety instructions/precautions

  1. Wear protective gloves.
  2. Wear safety glasses when cutting out window glass.

Pneumatic multicutter

  1. Always interrupt air supply when inserting or removing multicutter blade.

Electric multicutter

  1. Always interrupt power supply when inserting or removing multicutter blade.

Risk of injury from cutting wire tearing or becoming hot and from splinters of glass when cutting out bonded windows - AS67.00-Z-0004-01A

Wear protective gloves and eye protection.

Injury hazard

When cutting out the bonded window with the cutting wire, there is a risk of injuries to eyes and hands as a result of the cutting wire tearing or becoming hot and as a result of glass splinters jumping off.

Protective measures/guidelines

  1. Wear protective gloves.
  2. Wear eye protection when cutting out the window.

Safety information: Windows - AS67.00-Z-9999ZZ

MODEL all

Risk of injury caused by slipping when inserting blade in the multicutter and by glass splinters when cutting out bonded windows MODEL all AS67.00-Z-0001-01A Risk of injury from contusions to hands if window glass is not secured MODEL all AS67.00-Z-0002-01A Risk of injury from cutting wire tearing or becoming hot and from splinters of glass when cutting out bonded windows MODEL all AS67.00-Z-0004-01A Risk of injury from pinching or crushing hands and feet when working on windows. MODEL 210, 211, 212, 220, 221, 240, 397, 461, 463, 613, 671, 684... AS67.00-Z-0003-01A

Heated rear window, function - GF67.29-P-0003MCC

MODEL 451.3 /4

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Scheme 39: Heated rear window, function - GF67.29-P-0003MCC
Scheme 39: Heated rear window, function - GF67.29-P-0003MCC

Function requirements

  1. Circuit 15 On

Function

Actuation of the rear window heater switch is directly read in by the SAM control unit.

The SAM control module then supplies power to the heated rear window, for 10 min.

The integrated LED provides a status feedback message via the rear window heater switch.

Actuating the rear window heater switch again before expiration of the heating period deactivates the rear window heater.

Heated rear window (HRW), location of components GF67.29-P-0003-01MCC Electric wiring diagram for heated rear window * not for USA PE67.29-P-2000MCC * for USA only PE67.29-P-2000MCU SAM control unit, component description N10/10 * not for USA GF54.21-P-4157MCC * for USA only GF54.21-P-4157MCU Component description for the heater/air conditioning operating unit N23 Vehicles without code (I01) Air conditioning Plus GF83.40-P-3001MCC Vehicles with code (I01) Air conditioning Plus * not for USA GF83.40-P-3001MCD Vehicles with code (I01) Air conditioning Plus * for USA only GF83.40-P-3001MCU

450 589 08 63 00 Cutting wire - WS67.00-P-0020B

FG 65/67/Set B

MODEL 450, 451, 452, 454

Use

Cutting wire for cutting out glued windows and glass roof

Note. Cutting wire smart no.: 000 5177 V001 0000 00

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Scheme 40: 450 589 08 63 00 Cutting wire - WS67.00-P-0020B
Scheme 40: 450 589 08 63 00 Cutting wire - WS67.00-P-0020B

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452 589 00 99 11 Stone chipping cracker - WS67.00-P-0022-11B

FG67FG 27/Set B

MODEL 450, 451, 452

Use

Stone chipping cracker for increasing size of impact hole for repair preparation.

Note. Smart no.: 001 6322 V000 0000 00

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452 589 00 99 00 Glass repair box - WS67.00-P-0022B

FG 67/Set B

MODEL 450, 451, 452

Single part452 589 00 99 11 Stone chipping crackerFG67FG 27/Set BWS67.00-P-0022-11B

Use

Repair of stone chipping in laminated glass.

Note. Smart no.: 001 5780 V000 0000 00

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