Windshield: Service and Repair

Windshield Glass (76.81.40)

Special Service Tools
















Removal

1. Remove both A- pillar trim panels.
2. Remove both sun visors.
3. Remove the overhead console.
4. Remove the wiper pivot arm.
5. Remove the cowl panel grille.

6. CAUTION: Make sure the front windshield finisher insert is not bent on removal. Failure to follow this instruction may result in damage to the component.

Remove the windshield finisher insert.







7. Remove the windshield finisher.







8. Apply a suitable protective tape around windshield glass aperture to protect paintwork.







9. NOTE: Left-hand shown, right-hand similar

Apply a suitable protective tape to leading edge of headlining.







10. Place a suitable protective sheet over fascia and place a protecting board over sheet.
11. Prepare the cheese wire and cutting handle.
- Position cutting handle central tube fully upwards in handle.
- Cut a suitable length of cheese wire and pass one end through handle tube and locating aperture.
- Move cutting handle central tube downwards to secure cheese wire.

12. Using a suitable long bladed tool, penetrate Betaseal approximately 150 mm from the top of one A pillar.







13. Pass free end of cheese wire through penetration and install second cutting handle.







14. WARNING: When removing the windshield glass, personal protection must be worn. Failure to follow this instruction may result in personal injury.

CAUTION:
- Make sure the cheese wire cannot contact the paintwork while the the windshield adhesive is being cut. Failure to follow this instruction may result in damage to the vehicle.
- Make sure the cheese wire cannot contact the instrument panel while the the windshield adhesive is being cut. Failure to follow this instruction may result in damage to the vehicle.
- Make sure the cheese wire passes the Vehicle Identification Number (VIN) plate on the correct side. Failure to follow this instruction may result in damage to the component.
- When cutting, do not allow cheese wire to contact edge of windshield glass as this will crack the windshield glass.

NOTE: Apply cutting lubricant to the cheese wire frequently through out the cutting process.

With assistance and exercising care at the corners to avoid damaging paintwork, cut around the windshield glass commencing downwards and along the bottom.







15. With assistance and exercising care, remove the windshield glass.
1. Attach lifting handles to windshield glass.
2. Remove the windshield glass.







16. Remove lifting handles from windshield glass.
17. Remove cheese wire cutter from windshield glass aperture, remove cutting handles and discard cheese wire.

Installation

1. WARNING:
- If the windshield glass is being installed at a temperature of 23 degrees C (73 degrees F) or above make sure the vehicle is not driven for at least 1 hour after installation.
- If the windshield glass is being installed at a temperature of 11 degrees C (52 degrees F) make sure the vehicle is not driven for at least 1.5 hours after installation.
- If the windshield glass is being installed at a temperature of 5 degrees C (41 degrees F) make sure the vehicle is not driven for at least 2 hours after installation.
- If the windshield glass is being installed at a temperature below 5 degrees C (41 degrees F) use heat and make sure the windshield glass adhesive has set before the vehicle is driven.

NOTE: If the original windshield glass is to be installed remove the residual adhesive from windshield glass mating surface using the special tool.

Using the special tool, remove any residual adhesive from the body.







2. Remove the protective tape from around windshield glass aperture.







3. Apply glass primer to the mating face of the body flange.







4. Thoroughly clean windshield glass surface using Betawipe spirit.







5. Apply primer to mating face of windshield glass.







6. CAUTION: Make sure the front windshield finisher insert is not bent on installation. Failure to follow this instruction may result in damage to the component.

Install the insert to the windshield finisher.







7. CAUTION: Make sure the front windshield finisher insert is not bent on installation. Failure to follow this instruction may result in damage to the component.

Install the windshield finisher to the windshield.







8. Cut the nozzle of the JLM20452 glass bonding adhesive to achieve a triangular section bead 8 mm ( 0.32 in) wide by 10 mm (0.4 in) high.







9. NOTE: Follow the manufacturers operating instructions.

Using the special tool, apply a uniform bead of adhesive to the windshield glass edge commencing at bottom center and overlapping the ends approximately 14 mm (0.56 in).







10. CAUTION:
- When installing the windshield glass, do not strike it in any way as this will crack the windshield glass.
- Make sure the windshield glass does not move out of position in the windshield glass aperture.

With assistance carefully install windshield glass into the aperture. Align the windshield glass with the body markings and press firmly into place.







11. Remove the lifting handles.

12. CAUTION: Make sure the windshield glass does not move out of position in the windshield glass aperture.

Apply suitable tape to the top of the windshield glass.







13. Install the cowl panel grille.
14. Install the wiper pivot arm.
15. Remove protective tape from leading edge of headlining.







16. Remove the protective sheet and the protective board from the fascia.
17. Install the overhead console.
18. Install both sun visors.
19. Install both A-pillar trim panels.