Windows (Coupe): Removal & Installation Smart Fortwo II

Notes on removal/installation of windshield - AH67.10-P-1000-01MCE

Model 451.3/4

Adhesive kit for isopropanol cleaner

Scheme 2

Adhesive kit with heptane cleaner

Scheme 3

Use individual components as described in table below

Scheme 4

Deviation is not permissible, otherwise adhesive force of bonded connection is not ensured.

Allow corresponding primer to flash off for at least 10 minutes, however, for max. 15 minutes.

The crank window in the driver door must be opened during the curing time to prevent the component glued in from being pressed out by the air when the doors are closed. Avoid to open and close doors.

Designation Note Use Adhesive cartridge (4) Hot application: Short processing time Durability is achieved after approx. 2 h measured from the time the component is installed. The rated accident strength is achieved only after approx. 8 h. The adhesive cartridge (4) is heated in cartridge heater. Adhesive material for: Full roof (with code (E23) Full roof (FFO)) Glass roof (with code (E22) Glass roof (FFO)) Windshield Firewall segment Plastic primer (5) Apply with wool wiper (13). Allow primer to flash off for at least 10 - 15 minutes, otherwise the adhesive force of the bonded joint starts to decrease. Primer for: Full roof (with code (E23) Full roof (FFO)) Primer stick (6) PC primer Allow primer to flash off for at least 10 - 15 minutes, otherwise the adhesive force of the bonded joint starts to decrease. Primer for: Glass roof (with code (E22) Glass roof (FFO)) Windshield Firewall segment Body flange Heptane cleaner 3350 (7) Apply with cloth (9). Cleaner for primer surface: Full roof (with code (E23) Full roof (FFO)) Cleaning cloth (8) Cleaning cloth containing isopropanol and cleaning drying cloth Cleaner for primer surface: Glass roof (with code (E22) Glass roof (FFO)) Windshield Firewall segment Body flange Cloth (9) Color blue-green For applying: Heptane cleaner 3350 (7) Spacer (10) Spacer (10) for: Full roof (with code (E23) Full roof (FFO)) Glass roof (with code (E22) Glass roof (FFO)) Windshield Cutting wire (11) Cut out with cutting wire (11) and the two handles included in the window removal kit. To cut out: Full roof (with code (E23) Full roof (FFO)) Glass roof (with code (E22) Glass roof (FFO)) Windshield Firewall segment Application nozzle (12) Nozzle tips are already cut to size. Application of adhesive material in combination with adhesive cartridge (4) Wool wiper (13) Applying plastic primer (5)

Prepare window for installation - AR67.10-P-1000-03MCC

REPAIR MATERIALS

Adhesive kit for isopropanol cleaner

Scheme 5

The gluing area on the window must be absolutely free of dust and grease, flaws can lead to adhesion problems of the adhesive when glazing

1. Check surface of window for scratches and damage; replace if necessary.
2. Cut off residual adhesive material of window with scraper down to a height of approx. 2 mm. Remove adhesive material residues. Cut back adhesive residues on window max. 15 minutes before applying new adhesive bead, because the adhesive material on the cutting surface reacts to the ambient air which can lead to adhesion problems. When reinstalling removed window. Clean gluing area on window with cleaning rag (8) from repair kit. When installing a new window.
3. Repair damaged primer layer on window with primer stick (6) from repair kit. When reinstalling removed window. Allow primer to flash off for at least 10 - 15 minutes. Coat gluing area on window with primer stick (6) included in repair kit (max. 20 mm). When installing a new window. Allow primer to flash off for at least 10 - 15 minutes. Windshields are generally delivered with a viewing window on the bottom left. If the viewing window is not required, coat this area on the inside of the window with primer stick (6).

Scheme 6

1. Lay windshield (1) down on spacers on body flange, align windshield (1) at top and center at side. Cup suction tool Aid of helper required.
2. Attach suitable strips of adhesive tape (arrows) and cut at upper edge on windshield (1).
3. Remove windshield (1) from body flange Cup suction tool Aid of helper required.

REPAIR MATERIALS

Adhesive kit for isopropanol cleaner

Scheme 7

The gluing area on the window must be absolutely free of dust and grease, flaws can lead to adhesion problems of the adhesive when glazing

1. Check surface of window for scratches and damage; replace if necessary.
2. Cut off residual adhesive material of window with scraper down to a height of approx. 2 mm. Remove adhesive material residues. Cut back adhesive residues on window max. 15 minutes before applying new adhesive bead, because the adhesive material on the cutting surface reacts to the ambient air which can lead to adhesion problems. When reinstalling removed window. Clean gluing area on window with cleaning rag (8) from repair kit.
3. Repair damaged primer layer on window with primer stick (6) from repair kit. When installing a new window. When reinstalling removed window. Allow primer to flash off for at least 10 - 15 minutes. Coat gluing area on window with primer stick (6) included in repair kit (max. 20 mm). When installing a new window. Allow primer to flash off for at least 10 - 15 minutes. Windshields are generally delivered with a viewing window on the bottom left. If the viewing window is not required, coat this area on the inside of the window with primer stick (6).

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

MODEL 451.3 /4

Shown on model 451.3

Scheme 8

MODIFICATION NOTES

Removing Risk of injury due to tear or warming up of cutting wire and through glass splinters when cutting out glued windows Wear protective gloves and safety glasses. AS67.00-Z-0004-01A Notes on removal/installation of windshield AH67.10-P-1000-01MCE Notes on removal/installation of windows AH67.10-P-1000-02SM 1 Remove maintenance flap 2 Remove wiper arms AR82.30-P-6100MCC 3 Remove inside rearview mirror * not for USA AR68.40-P-0001MCC * for USA only AR68.40-P-0001MCU 4 Remove rain/light sensor For vehicles with code (V54) Rain/light sensor AR82.30-P-7800MCC 5 Cover dashboard with suitable protective cover 6.1 Cut out windshield (1) with "Roll out" window removal tool When using "Roll out" window removal tool. Aid of helper required to remove windshield (1) from body flange. Cutting wire is included in TS adhesive. "Roll out" window removal tool Cup suction tool AR67.10-P-1000-11MCC TS adhesive (with isopropanol cleaner) *BR00.45-Z-1041-02B 6.2 Cut out windshield (1) "Veritrac" window removal tool When using "Veritrac" window removal tool. Mask off body flange, front edge of vehicle roof as well as detachable parts in cutting area using masking tape to prevent damage from cutting wire. Aid of helper required to cut out and remove windshield (1). Cutting wire is included in TS adhesive. Cutting wire Cup suction tool see scheme 19 TS adhesive (with isopropanol cleaner) *BR00.45-Z-1041-02B Checking 7 Check bonding area on body flange for paint chipping Damage from removing windshield (1) can be repaired with approved materials. Notes on repair paintwork in bonding area of windows and components AH98.00-P-9408-07MCC 8.1 Repair paint chipping on body flange with approved materials On paint chips up to approx. 2 cm 2. Do not apply basic or clear varnish in boding area. General notes on touch-up applicators and paint spray cans AH98.00-P-9409-06SM 8.2 Renew paintwork structure on body flange On paint chips larger than approx. 2 cm 2. AR98.00-P-0900MCC Install 9 Prepare body flange for installation of window The gluing area on the body flange must be absolutely free of dust and grease to prevent a decrease in the gluing force when installing window. Wet/dry vacuum cleaner AR67.10-P-1501-01MCC TS adhesive (with isopropanol cleaner) *BR00.45-Z-1041-02B 10 Align windshield (1) in the body opening Aid of helper required. Cup suction tool AR67.10-P-1000-04MCC 11 Prepare windshield (1) for glazing The gluing area on the windshield (1) should be absolutely free of dust and grease to prevent adhesion problems of the adhesive material. AR67.10-P-1000-03MCC TS adhesive (with isopropanol cleaner) *BR00.45-Z-1041-02B 12 Open crank window in driver door The crank window in the driver door must be opened during the curing time to prevent the windshield (1) from being pressed out by the air when the doors are closed. 13 Apply adhesive material Install windshield (1) on body flange within 2 minutes after applying adhesive material, to prevent adhesion problems of the adhesive material. If the paintwork structure on the body flange is renewed, apply adhesive material on body flange for corrosion protection reasons. 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. Uniformly apply adhesive bead at a height of approx. 12 mm. AR67.10-P-1000-08MCC Intermediate piece Cartridge gun (Scheme 7) TS adhesive (with isopropanol cleaner) *BR00.45-Z-1041-02B 14 Install windshield (1) Aid of helper required. Fasten windshield (1) with suitable adhesive tape. Cup suction tool AR67.10-P-1503-01MCC 15 Install rain/light sensor For vehicles with code (V54) Rain/light sensor AR82.30-P-7800MCC 16 Install rearview mirror unit * not for USA AR68.40-P-0001MCC * for USA only AR68.40-P-0001MCU 17 Install wiper arms AR82.30-P-6100MCC 18 Install maintenance flap 19 Clean windshield (1) 20 Connect Star Diagnosis, read out fault memory, initialize rain/light sensor For vehicles with code (V54) Rain/light sensor AD00.00-P-2000-04MCC

Scheme 9

Scheme 10

Scheme 11

Scheme 12

Scheme 13

Scheme 14

Scheme 15

REPAIR MATERIALS

Prepare body flange for installation of window - AR67.10-P-1501-01MCC

REPAIR MATERIALS

Adhesive kit for isopropanol cleaner

Scheme 16

The gluing area (2) on the body flange (1) must be absolutely free of dust and grease to prevent paint adhesion problem of the adhesive material when glazing. Cut back remaining adhesive material on body flange (1) max. 15 minutes before applying new adhesive bead, because the adhesive material on the cutting surface reacts with the ambient air which can lead to adhesion problems

Scheme 17

Scheme 18

1. Cut off residual adhesive material on body flange (1) down to a height of approx. 2 mm using suitable scraper. Remove adhesive material residues.
2. Clean painted adhesive surface on body flange (1) with cleaning rag from repair kit and rub dry with rag.
3. Repair paint damage at body flange (1) with primer applicator.
4. Apply primer to body flange (1) with primer stick from repair kit in areas where residual adhesive material is missing or damaged. s Allow primer to flash off for at least 10 minutes.
5. Install spacers (10) as shown in illustration.
6. Clean working area. Wet/dry vacuum cleaner