Windshield: Service and Repair
WINDSHIELDWARNING
WINDSHIELD SAFETY PRECAUTIONS
WARNING: DO NOT OPERATE THE VEHICLE WITHIN 24 HOURS OF WINDSHIELD INSTALLATION. IT TAKES AT LEAST 24 HOURS FOR URETHANE ADHESIVE TO CURE. IF IT IS NOT CURED, THE WINDSHIELD MAY NOT PERFORM PROPERLY IN AN ACCIDENT.
- URETHANE ADHESIVES ARE APPLIED AS A SYSTEM. USE GLASS CLEANER, GLASS PREP SOLVENT, GLASS PRIMER, PVC (VINYL) PRIMER AND PINCH WELD (FENCE) PRIMER PROVIDED BY THE ADHESIVE MANUFACTURER. IF NOT, STRUCTURAL INTEGRITY COULD BE COMPROMISED.
- DAIMLERCHRYSLER DOES NOT RECOMMEND GLASS ADHESIVE BY BRAND. TECHNICIANS SHOULD REVIEW PRODUCT LABELS AND TECHNICAL DATA SHEETS, AND USE ONLY ADHESIVES THAT THEIR MANUFACTURES WARRANT WILL RESTORE A VEHICLE TO THE REQUIREMENTS OF FMVSS 212. TECHNICIANS SHOULD ALSO INSURE THAT PRIMERS AND CLEANERS ARE COMPATIBLE WITH THE PARTICULAR ADHESIVE USED.
- BE SURE TO REFER TO THE URETHANE MANUFACTURER'S DIRECTIONS FOR CURING TIME SPECIFICATIONS, AND DO NOT USE ADHESIVE AFTER ITS EXPIRATION DATE.
- VAPORS THAT ARE EMITTED FROM THE URETHANE ADHESIVE OR PRIMER COULD CAUSE PERSONAL INJURY. USE THEM IN A WELL-VENTILATED AREA.
- SKIN CONTACT WITH URETHANE ADHESIVE SHOULD BE AVOIDED. PERSONAL INJURY MAY RESULT.
- ALWAYS WEAR EYE AND HAND PROTECTION WHEN WORKING WITH GLASS.
CAUTION: Protect all painted and trimmed surfaces from coming in contact with urethane or primers. Be careful not to damage painted surfaces when removing moldings or cutting urethane around windshield.
REMOVAL
1. Remove wiper arms.
2. Remove headliner.
3. Remove rear view mirror.
CAUTION: Cover instrument panel and vents to protect against splinters and damage.
Fig. 3:
4. Using a trim stick C-4755 or equivalent,remove windshield seal. (Fig. 3)
CAUTION: Fabricate a protection guard from 2 mm sheet plastic or equivalent to protect rubber instrument panel from damage.
Fig. 4:
5. Place protection guard between windshield and instrument panel seal. (Fig. 4)
Fig. 5:
6. Using a windshield cut-out wire separate the adhesive. (Fig. 5)
7. Carefully remove windshield.
INSTALLATION
WARNING: Allow the urethane at least 24 hours to cure before returning the vehicle to use.
CAUTION: Roll down the left and right front door glass and open the rear glass slider (if available) before installing windshield to avoid pressurizing the passenger compartment if a door is slammed before urethane is cured. Water leaks can result. The windshield fence should be cleaned of most of its old urethane bonding material. A small amount of old urethane, approximately 1 mm in height, should remain on the fence. Do not grind off or completely remove all old urethane from the fence, the paint finish and bonding strength will be adversely affected.
Windshield Preparation - Installing A Previously Installed Windshield
Fig. 6:
1. Level old bead of windshield adhesive to a thickness of approximately 1 mm (0.04 in.) and remove loose adhesive. (Fig. 6)
Fig. 7:
2. Position windshield seal onto windshield starting at one corner and quickly moving up and down. (Fig. 7)
CAUTION: Never moisten windshield seal with lubricants to facilitate installation.
3. Position windshield in center of windshield opening.
Fig. 8:
4. Apply adhesive tape to the locations shown to aid with final installation. (Fig. 8)
5. Verify windshield gap is parallel to with windshield.
6. Cut tape with a sharp knife and remove windshield.
7. Clean and dry area of glass to be re-glued with a suitable glass preparation solvent and rag.
8. Using a flash light, verify that glass primer is without damage.
Fig. 9:
9. Re-prime any damaged area. If old adhesive has been exposed for more than 12 hours, entire adhesive area needs to be re-primed. (Fig. 9)
10. Allow primer to air dry for at least 10 minutes.
11. Using a flash light, verify that glass primer is without damage.
Windshield Preparation - Installing A New Windshield
1. Clean and check windshield for damage.
2. Position windshield seal onto windshield starting at one corner and quickly moving up and down. (Fig. 7)
CAUTION: Never moisten windshield seal with lubricants to facilitate installation.
3. Position windshield in center of windshield opening.
4. Apply adhesive tape to the locations shown to aid with final installation. (Fig. 8)
5. Verify windshield gap is parallel to with windshield.
6. Cut tape with a sharp knife and remove windshield.
7. Clean and dry area of glass to be re-glued with a suitable glass preparation solvent and rag.
8. Apply primer to gluing surface at windshield seal. (Fig. 9)
9. Allow primer to air dry for at least 10 minutes.
10. Using a flash light, verify that glass primer is without damage.
Windshield Opening Preparation
1. Clean and vacuum windshield opening.
Fig. 10:
2. Level old bead of windshield opening adhesive to a thickness of approximately 1 mm (0.04 in.) and remove loose adhesive. (Fig. 10)
3. Clean and dry area of windshield opening to be re-glued with a suitable glass preparation solvent and rag.
Fig. 11:
4. Re-prime any damaged area. If old adhesive has been exposed for more than 12 hours, entire adhesive area needs to be re-primed. (Fig. 11)
5. Allow primer to air dry for at least 10 minutes.
Windshield Installation
Fig. 12:
1. Apply bead of glue with a triangular nozzle directly to the windshield seal starting at bottom in center of windshield. (Fig. 12)
CAUTION: Always apply bead of adhesive to the windshield. Always install the windshield within 5 minutes after applying adhesive.
Fig. 13:
2. Allow end of adhesive bead to run out parallel to the start of the bead and smooth ends flush. (Fig. 13)
3. Lift windshield into place in the center of the windshield opening and use the tape as a guide to aid installation of the windshield into the center of the cutout.
4. Carefully lay down windshield and press on.
CAUTION:
- It is no longer possible to move the windshield after installation. The windshield should never be pressed into place by more than one person, because the windshield can break if pressed simultaneously on both sides.
- Roll down the left and right front door glass and open the rear glass slider (if available) before installing windshield to avoid pressurizing the passenger compartment if a door is slammed before urethane is cured. Water leaks can result.
5. Install the rear view mirror.
6. Install the headliner.
7. Install the wiper arms.