C5CG0NK1 - 206

REMOVAL - REFITTING REAR SCREEN

1 - PARTS REQUIRED

[1] : Lower shims (x 2) .

[2] : Upper shims (x 2) .

2 - REMOVAL

2 - 1 - WITH THE TAILGATE CLOSED

Protect the four corners and the lower part of the screen aperture (1) with adhesive tape .

Remove : The windscreen wiper arm .

2 - 2 - WITH THE TAILGATE OPEN

Protect :

• the rear seat
• the rear parcel tray
• the luggage compartment lid

Remove :

• THE TAILGATE TRIM
• THE WIPER MOTOR
• the grommet in the wiper pin
• the stops for the rear parcel shelf
• the demisting connections : seat the tabs against the screen

2 - 3 - CUT OUT THE FIRST ZONE FROM (A) TO (B)

WARNING : when cutting out, avoid rubbing the wire on the dropped flange .

Route the awl through the bead of adhesive from the inside towards the outside, at (A) .

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

THREAD THE CUTTING OUT WIRE INTO THE COILING DEVICE [1A] AND TIGHTEN IT .

Thread the cutting out wire under the screen from (A) to (B) .

Route the awl through the bead of adhesive from the inside towards the outside, at (B) .

Thread the cutting out wire into the awl and route it towards the inside .

Secure the end of the wire on the swivel joint (2 ) .

Move the coiling device as shown on figure and fit the return roller .

Route the wire as indicated on the diagram .

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

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

Cut out in accordance with the above view, in the same conditions as previously (Up to point (B)) .

2 - 4 - CUTTING OUT OF THE 2ND ZONE FROM (B) TO (A)

Route the awl through the bead of adhesive from the inside towards the outside, at (B) .

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

THREAD THE CUTTING OUT WIRE INTO THE COILING DEVICE [1A] AND TIGHTEN IT .

Thread the cutting out wire under the screen from (B) to (A) .

Route the awl through the bead of adhesive from the inside towards the outside, at (A) .

Thread the cutting out wire into the awl and route it towards the inside .

Secure the end of the wire on the swivel joint (3 ) .

Move the coiling device as shown on figure and fit the return roller .

Route the wire as indicated on the diagram .

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

Move the coiling device as shown on the figure and continue cutting out .

Move the coiling device as shown on figure and fit the return roller .

Route the wire as indicated on the diagram .

Continue the cut until the 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 .

NOTE : for the following operation 2 people are necessary (to retrieve the rear screen) .

Cut out in accordance with the above view, in the same conditions as previously (Up to point (A)) .

REMOVE THE SCREEN USING THE SUCTION CUPS [4] .

2 - 5 - PREPARATIONS FOR REFITTING THE GLASS

In the case of glass cut out without any damage .

In the event of using an intact piece of glass :

• CUT AWAY THE REMAINING ADHESIVE AND SEALANT FROM THE GLASS AND AROUND THE EDGE OF THE PANEL WITH THE ELECTRIC KNIFE FITTED WITH BLADE NO. [15] OR NO. 146, IN ORDER TO OBTAIN A SMOOTH SURFACE, BUT TAKING CARE NOT TO REMOVE QUITE ALL OF THE RESIDUE

The residue of the product serves as a base, providing adhesion for the product and for application of the sealant .

WARNING : do not apply primer to the surface to be bonded and do not treat it with the cleaning solvent .

In the event of new glass :

• clean the bonding area around the edge of the glass with degreasing agent
• apply the glass primer selected from the adhesive kit

DRYING TIME: APPROXIMATELY 10 MINUTES .

Windscreen aperture flange reworked :

• if the windscreen aperture flange has been reworked or replaced, the layers of paint should be built up again and, if necessary, the anticorrosion protection operations should be carried out
• first clean the reworked area with cleaning solvent selected from the bonding kit and then apply the metal primer

DRYING TIME: APPROXIMATELY 10 MINUTES .

2 - 6 - PREPARATION ON THE TAILGATE

Fit the shims [1] at C on the tailgate .

Fit the shims [2] at D on the tailgate ; Retain the shims with a ball of mastic .

Take care to observe the direction of fitting of the shims [2] .

Remove the adhesive strip from the shims [2] .

2 - 7 - LAYOUT OF THE REAR SCREEN ON THE TAILGATE

Two people are required to offer up and fit the glass on the tailgate .

FIRST OF ALL ALIGN THE GLASS AT THE TOP OF THE TAILGATE + (CORNERS) AND APPLY IT TO THE SHIMS [2] BY PRESSING IN ORDER TO ENSURE THAT THE SHIMS [2] ARE BONDED TO THE GLASS .

Place adhesive strips at the top and the side, which will serve as reference points for the final positioning of the rear screen .

Cut out the markers ; Remove the rear screen .

3 - REFITTING

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 (WITH THE PLIERS [7]) .

Apply the bead of adhesive :

• at B 10 mm from the edge
• at C 50 mm from the edge
• at D 20 mm from the edge

IMPERATIVE : NO MORE THAN 8 MINUTES MUST ELAPSE BETWEEN APPLYING THE MASTIC AND POSITIONING THE GLASS (for the quick bonding adhesive mastics) .

For the fitting operation, two people are required .

OFFER UP THE GLASS TO THE APERTURE OPPOSITE THE MARKERS (Using the suction cups [4] ) .

EXERT A CONSTANT PRESSURE USING THE SUCTION CUPS WITH WIRES [5] .

ALLOW TO DRY ACCORDING TO THE INSTRUCTIONS IN THE ADHESIVE KIT .

Proceed in the reverse order to removal .

Check :

• the operation of the screen wiper
• the operation of the heated screen
• clean the glass