Windshield: Service and Repair

Direct Glazing

Removal of Glass
Position vehicle in workshop. Ensure workshop temperatures are between 18-25 degrees C.







Prise off exterior finishing trim releasing it from retaining clips taking care not to create bending stress on the finisher.







Remove retaining clips from the glass edge.

Note:
- This is not considered to be necessary if using the reciprocating knife method of removal. Clips may also be too embedded for removal.
- Protect all vehicle interior trim with covers and mats, removing interior trim from around the glazing apertures as is considered prudent.
- Disconnect aerial antennae/heated screen connections.
- Disconnect and remove HMSL (High Mounted Stop Light). Backlights only.
- The wire removal technique requires full access to screen aperture.
- The reciprocating knife removal technique requires minimal removal of trim especially in the removal of front screens.

Cheese wire (piano wire) Technique
Protect internal and external painted surfaces with masking tape around the apertures.

Fix a length of wire to one cutting handle.







Force spike through sealing compound and pass wire through.







Fit remaining handle to loose end of wire, then pull the wire through the sealing compound taking care to avoid grazing the painted aperture and glass edge.

Some additional separation using a cutting blade may be required to free the glass. Alternatively use a cold knife technique instead of the wire.

Note:
- Damage to screen sealing rubbers will be inevitable.
- The use of power tools designed for this purpose is a far more efficient method and considerably safer for operators and potential vehicle damage.

Reciprocating Powered Knife
Select the most suitable blade from the kit provided with the cutting tool.
Sharpen the tip of the blade on the wet stone provided, to give it a keen edge.







Note: Long blades for long reach, short blades where access is easy.

Determine the depth of the original adhesive by comparing measurements taken from inside and outside the screen.







Set the blade depth accordingly so that the blade will not mark the body aperture when cutting.

Note:
- See matrix, service equipment, this section for blade selection.
- When setting depth control allow for 6 mm of blade travel.







Insert the blade between body flange and glass.

Apply soapy solution DGX Cutting Fluid and water around the aperture sprayed from a spray bottle provided with the BTB kit.

Cut carefully around the aperture continually lubricating the cut zone.

Note:
- Depending upon access and length of reach the blade may need to be changed during the cutting operation to ensure complete penetration and separation.
- Avoid stresses at corners by cutting almost to depth of sealant around radius. Finally complete the cut.







Fit and align glass lifting suction cups to screen.

Remove glass and place external surface down on a padded trestle.







Carefully clean surplus adhesive sealant from body flange, using a sharp blade. B.T.B. WK6 blade.

Cut down sealer to a depth of between 1 mm-2 mm if sound. If adhesion is poor, remove sealant completely.

Avoid damaging the painted flange.

Note: If paintwork is damaged, it is of paramount importance to prevent corrosion and water leaks, that two component paintwork repairs are carried out.







Remove residual sealant from glass if screen is to be replaced as, for example, in the case of quarter glass removal for panel fitting.

Cut to between 1 mm-2 mm thickness if sound. If adhesion is poor, remove sealant completely. If unsure of the stability or adhesion it is advisable to remove all residues.

Note: The ceramic frit,(obscuration band) will not be damaged by the blade.

Apply the requisite primers and cleaners.







Consult the Gurit Essex product data sheets for specific usage and procedures.

Installation of Glass







Fit the two component cartridge pack into the Beta Gun.

Note:
- The Beta Gun, adhesive sealant application system is an electric motor driven device which will apply an equal force to both cartridges of the pack, ensuring a dynamically controlled mix of the two ingredients of the adhesive sealant.
- The rate of extrusion of the mixed adhesive and accelerator is controlled by trigger pressure.

Position the glass to enable all round access.







Apply a single continuous triangular shaped bead of adhesive to the glass perimeter / primed area.

Note: The base of the triangle should be between 3 mm-6 mm and height 12 mm - 16 mm(max)

Fit suction lifting pads to the glass.

Fit glass to the aperture immediately after the bead is applied.

Position glass into aperture within 6-8 minutes maximum.

Remove any dirt or finger marks from the glass with a Isopropanol IPA type cleaner (3500).

Uncured residues of sealant can be cleaned away easily. Cured residues will need mechanical removal.

Ensure the vehicle remains stationary in the workshop.

Open all vehicle glasses and close doors carefully to avoid pressurizing the cabin during the uncured stage.

DRIVE AWAY TIME

WITHOUT AIRBAG
Temperature above 5 deg. C.

30 minutes

WITH TWIN AIRBAG
Temperature above 5 deg. C

60 minutes with the application of heat around aperture.

120 minutes without application of heat around aperture.

For further information on curing times contact GURIT ESSEX UK LIMITED R

Refit interior/exterior trim as required.