C5CG14K1 - 607

REMOVAL - REFITTING REAR SCREEN

1 - TOOLING

[1] FEIN electric knife assembly .

Contents of kit :

[1a] electric knife only
[1b] stone to be sharpened
[1c] spanner

[2] Shovel blade N° 146 .

[3] Jointed suction caps .

[4] Suction caps with wires .

[5] Set of glass components :

[5a] : 1 inertia device with roller
[5b] : 1 roller guide with counter pressure (half suction hole)
[5c] : 1 awl
[5d] : 1 handle
[5e] : 1 square section cutting wire

2 - BONDING KIT

[6] Adhesive kit (quick set) :

[6a] adhesive mastic (220 ml), or (450 ml) X
[6b] primer for red panels
[6c] primer for green glass
[6d] yellow degreaser
[6e] applicator pad
[6f] piano wire
[6g] cleaning paper
[6h] nozzles

[7] gun .

Use (X) :

220 ml : quarter light
450 ml : windscreen, or, rear screen

[8] Adhesive kit (quick set) :

[8a] operating instructions
[8b] mixer
[8c] adhesive mastic (400 ml)
[8d] yellow degreaser
[8e] protective gloves
[8f] cleaning paper
[8g] piano wire
[8h] glass primer/black paint
[8i] nozzles
[8j] applicator pad

[9] gun .

NOTE : the following single component adhesives can be used .

[10] Compressed air gun .

[11] Cartridge heater (To pre-heat the ultra-rapid cartridges) .

[12] Bonding kit :

ultra-rapid cartridge
rapid cartridge
standard cartridge

3 - REMOVAL

Remove :

Disconnect the rear screen electrical connections .

Fold the connection terminals back against the glass and towards the centre of the vehicle .

NOTE : in the event that the rear screen is retrieved, place adhesive strips (1) as shown above, and cut them in B .

Attach the cutting-out wire to the mounting 2 (maximum length of bolt 10 mm, at the roof bar mounting points) .

Pass the wire under the rear screen following A, all around the edge .

Pass the awl through the bead of adhesive, in the top left corner of the rear screen .

Thread the cutting wire into the awl and pass it towards the interior (approximately 50 cm) .

Secure the end of the cutting wire (3) in the winding device .

WARNING : when tensioning the cutting wire, ensure that the wire is placed under the rear screen correctly .

Cut the first section to the centre of the rear screen .

WARNING : at the slightest resistance of the wire on cutting, slacken it and help it to pass the obstacle (support shims, excessively thick bead of adhesive or panel junction) .

Move the winding device as indicated on the diagram and install the guide pulley in the upper rounded section of the glass .

Route the cutting wire as indicated on the diagram .

Cut out the glass until the cutting wire is no longer guided by the guide pulley .

Then, remove the guide pulley and continue the cut .

Cut out in accordance with the above view, in the same conditions as previously .

Move the winding device [5] as indicated on the diagram and finish the cut .

Remove the rear screen using double suction cups [3] .

4 - REFITTING

For all the following operations, keep the boot lid open as shown in fig. .

4 - 1 - PREPARATION OF THE FLANGE AND OF THE REAR SCREEN

Protect the rear shelf frame and the seats .

Fit blade [2] no.146 to the electric knife .

Deburr the beads of adhesive on the rear screen and the flange .

Replace the 2 lower shims which serve as stops for the rear screen .

Offer up the rear screen onto the aperture .

NOTE : if the rear screen is replaced, centralise the screen and position adhesive strips (4) as shown above, then cut the strips .

Remove the rear screen .

Touch up with anti-corrosion product .

Degrease the flange and the rear screen using a product chosen from the bonding kit .

Allow to dry for 10 mn .

Apply the metal and glass primers selected from the adhesive kit .

Allow to dry for 10 mn .

4 - 2 - BONDING

Fit the mastic mixer assembly to the extruder gun .

Take the nozzle supplied in the bonding kit .

Cut the nozzle to 8 mm dia. at 12 mm from the tip .

Apply the bead of adhesive :

from point C to point D : 7 mm from the upper seal
from point E to point F, from point Q to point R : 7 mm from the side seal
from point G to point H, from point K to point L, from point O to point P : 26 mm from the edge of the glass
from point I to point J, from point M to point N : 36 mm from the edge of the glass

IMPERATIVE : no more than 8 minutes must elapse between applying the mastic and positioning the glass (for the quick bonding adhesive mastics) .

Position the rear screen in relation to the adhesive tape .

Exert a constant pressure using the suction cups with wires [4] .

Allow to cure for 30 minutes before handling .

Connect : The electrical connections .

Check :

the operation of the rear screen demister
the operation of the radio (good reception from the aerial)

Proceed in the reverse order to removal .