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Supplement, Fall 1999

The CuttingEDGE
new car installations


Windshield Installation on the
1999 Mercedes S 500

by Shawn McNally


Replacing the windshield on the 1999 Mercedes S 500 is relatively straightforward. Take your time with the removal process. None of our aftermarket suppliers carried the rain sensor reattachment kits, so we purchased an OEM windshield from our local dealer. We have since learned a reattachment kit is available through Precision Replacement Parts. Do not assume the rain sensor attachment kit is already on the windshield.


Removing the Moulding

Remove the felt-covered weather strip along the A pillars. You will find four Phillips head screws that hold down the side moulding. You need to remove them. Pull the moulding towards the outside of the vehicle to release the plastic clips. Once the moulding is loose, lift up the bottom and pull down the moulding. This will release the top. To remove the top moulding, use a chrome removal tool that releases it from the five metal sandwich clips.

You need a 3/16-inch Allen Key to remove the driver’s side wiper. The Allen Screw is hidden under a small cap at the rear of the wiper arm (not the wiper assembly). Remove the screw. Pull the wiper arm toward the drivers’ side of the car. The passenger side wiper is held to the spline with a 17-mm nut (you must use a socket). Remove the nut, then pull up on the wiper arm to remove.

To remove the cowl, you must first remove the nine Phillips head screws and plugs along the top of the it. There is one screw hidden behind the drivers’ side wiper assembly and it must also be removed. On the passenger side rear of the engine compartment, there is a large black cover containing the air filter. Remove the four large Phillips head screws that hold this cover in place. Move the cover forward enough to access the plastic clips on the bottom edge of the cowl and lift up on the clips to release them. Also, replace the filter cover before closing the hood. If you don’t do this, the result could be damage the filter cover and car hood.


Removing the Windshield

Use a cold knife on the top and side of the windshield. This will give you clearance to access the plug on the rain sensor. Gently pinch the edges of the plug and pull out of the sensor. To create a gap between the windshield and the dash, use a block between the A pillars and the windshield. Using a removal tool, start cutting from the passenger side corner to the center of the windshield. Repeat the process on the drivers’ side. Once the windshield is out you must remove the sensor box from the windshield. There are four clips on the sensor box. Pull out on the clips. Gently rock the sensor box from side to side. This will remove it from the glass sensor that is attached to the old windshield. Strip the pinchweld leaving a thin bead of urethane.


Installing the Windshield

Placing this windshield requires three people. The windshield has to be held in place approximately 2 inches from the urethane on the top in order to plug in the sensor. I recommend using a rapid cure urethane on this vehicle because there are no setting blocks. Once you have set the windshield in place use masking tape on the top driver and passenger sides to hold the windshield in place until the urethane cures enough to support the glass. You can now put the car together using the removal steps in reverse. n


Reports from the field

 Some installers have been able to install the windshield with one person. The rain sensor and wires can be connected after installing the glass. This eliminates the need for holding the windshield in place while a technician connects the wires from the inside.

Shawn McNally is with The Extractor of Alberta, Canada.


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