| Removal and Installation | Fein cutter blade No. 6 39 03 143 01 3 | | Fein cutter blade No. 6 39 03 081 01 3 | | Fein cutter blade No. 6 39 03 113 02 2 | | Fein oscillating cutter | FDEP No. 2583391 | | Hot air gun | FDEP No. 1561950 | | Mixer/applicator gun | FDEP No. 2650730 | Remove |  | CAUTION: Disconnect the battery negative lead. | | | |  | NOTE: Should the ambient temperature fall below 10°C, heat the cartridges for approximately 15 minutes by placing them on a warm radiator, or by using a heat gun set at approximately 25°C. | 1. Heat the adhesive if required. | | | 2. Remove the wiper arm assembly (one nut). 3. Open the tailgate and remove the parcel shelf. | | | 4. Remove the parcel shelf support cord clips (one each side). Punch out the centre pin. | | | 5. Remove the tailgate lower panel (ten screws). | | | 6. Pull off the tailgate upper panel (four clips). | | | 7. Detach the gas struts. Prise out the spring and push the strut off. | | | 8. Pull off the side panels (four clips). 9. Refit the gas struts. | | | 10. Remove the washer jet. • Pull off the flexible hose. • Prise off the washer jet. | | | 11. Disconnect the heated screen connectors (one each side). | | | 12. Unclip the wiring loom (four clips and one tie wrap). | | | 13. Detach the applique panel (ten nuts). | | | 14. Remove the applique panel. • Disconnect the two applique panel light multiplugs. • Detach the two applique panel light multiplug housings. | | | 15. Remove the wiper arm motor (three nuts, one multiplug and one ground lead). | | | 16. Detach the flexible loom grommets (one each side). 17. Attach a length of string to the wiring loom and remove the loom from the tailgate. 18. Pull the washer jet pipe out of the tailgate. | | | 19. Detach the weatherseal at the top of the tailgate aperture. | | | | | NOTE: A second technician will be required to support and carry the tailgate in the next operation. | 20. Detach the gas struts and remove the tailgate (four bolts). 21. Rest the tailgate on a bench (inside facing upwards). | | | 22. Fit blade number 6 39 03 143 01 3 set at 30 mm to the Fein cutter. | | | |  | WARNING: Always wear gloves and eye protection when working with the glass cutting tool as the cutting operation may produce splinters. Ear defenders should be worn when using the Fein cutter. | 23. From inside the tailgate, cut along the lower edge of the glass. | | | 24. Set blade number 6 39 03 143 01 3 at the full extent of travel (36 mm). | | | | | WARNING: Always wear gloves and eye protection when working with the glass cutting tool as the cutting operation may produce splinters. Ear defenders should be worn when using the Fein cutter. | 25. From the outside of the tailgate, cut along the top edge of the glass 100 mm either side of the washer jet hole. 26. Fit blade number 6 39 03 081 01 3 to the Fein cutter. | | | | | WARNING: Always wear gloves and eye protection when working with the glass cutting tool as the cutting operation may produce splinters. Ear defenders should be worn when using the Fein cutter. | 27. From the outside of the tailgate, cut along the sides and the remainder of the top edge of the glass. | | | | | CAUTION: Care must be exercised not to contact the tailgate metal when cutting along the lower corners of the tailgate glass. | 28. From inside the tailgate, cut the lower corners of the tailgate glass. 29. Lift the tailgate off the glass. | Install | | | NOTE: A second technician will be required to support and carry the tailgate in the next operation. | 30. Refit the tailgate (four bolts) and attach the gas struts. 31. Refit the weatherseal, washer jet pipe and wiring loom to the tailgate. 32. Refit the wiper arm motor and the applique panel. | | | | | CAUTION: Avoid touching the trimmed surface as this will inhibit the new adhesive from bonding. | 33. Remove the excess PU adhesive from the aperture using the Fein cutter fitted with blade number 6 39 03 113 02 2. Carefully trim the remaining PU adhesive from the window aperture to leave approximately 1 mm of trimmed PU adhered to the bodywork. 34. If the original glass is refitted, remove the excess PU adhesive from the glass as described in the previous step. | | | | | WARNING: To ensure that the PU adhesive cures, it is essential that all bonding surfaces are free of all moisture. | 35. Using a heat gun, apply warm air (25°C) to the window aperture and glass bond line to remove all traces of moisture. 36. Prepare the glass, window aperture and trimmed PU adhesive in accordance with the instructions supplied with the adhesive kit. | | | | | NOTE: Discard the first 10 cm (4in) of PU adhesive as this may have a reduced working time. | | | NOTE: To avoid water leaks, any breakage in the continuous bead should be overlapped by 20 mm (0.75in). | 37. Apply the PU adhesive in a continuous bead of between 8 and 10 mm height to the tailgate window flange along the bond line. | | | 38. Fit the tailgate glass. • With the aid of another technician, use suction pads to carefully lift the glass and align it in position over the window flange. • Firmly and evenly press into position. | | | 39. Should the ambient temperature fall below 10°C, use a heat gun at a distance of approximately 5 cm from the substrate and apply warm air (25°C) continuously for 15 minutes (inside or outside the vehicle). 40. Refit the remaining components in reverse order. 41. Check for leaks and correct as necessary. | |
