Removal and Replacement

Windshield Glass (76.81.40)

Special Service Tools







Removal

1. Remove battery cover and disconnect ground cable from battery terminal.
2. Remove interior mirror.
3. Remove wiper arm and blade assembly.
4. Remove plenum chamber cover.
5. If heated windshield is fitted:
- Disconnect LH power supply cable from connector located on secondary bulkhead.







6. If heated windshield is fitted:
- Disconnect RH power supply cable from connector located on secondary bulkhead.







7. Slacken and remove RH water deflector securing bolt and remove deflector.







8. Slacken and remove LH water deflector securing bolt and remove deflector.







9. Remove windshield finisher.
10. Marking the positions with masking tape, remove windshield finisher securing clips from edge of glass.
11. Remove each A post upper trim by carefully easing the three spring clips free.







12. Remove roof console.
13. Remove sun visors.
14. Apply suitable protective tape around windshield aperture to protect paintwork.







15. Apply suitable protective tape around leading edge of headlining.







16. Prepare cheese wire and cutting handle.
- Position cutting handle central tube fully upwards in handle.
- Cut a suitable length of cheese wire 42-001A-01 and pass one end through handle tube and locating aperture.
- Move cutting handle central tube downwards to secure cheese wire.

17. Using a suitable long bladed tool, penetrate Betaseal approximately 6in (150 mm) from top of one A post.







18. Remove tool, pass free end of cheese wire through penetration and fit second cutting handle.







19. Place a suitable protective sheet over fascia and place a protecting board over sheet.
20. With assistance and exercising care at corners to avoid damaging paintwork, cut around windshield commencing downwards and along the bottom.







21. Fit lifting handles to glass and with assistance lift windshield clear of vehicle and place on cloth covered bench.







22. Remove lifting handles from glass.
23. Remove cheesewire cutter from windshield aperture, remove cutting handles and discard cheesewire.
24. Remove protective board from fascia, leaving protective sheet in position.
25. Exercising care not to damage paintwork, use vibroknife to remove residual sealant from body flange.







26. Remove protective cloth from fascia.
27. Remove protective tape from windshield aperture flange.

Installation

1. If original windshield is to be refitted:
- Remove residual sealant from glass mating surface using a suitable scraper.
- Check installation of the two spacer buttons at bottom of glass and replace if they are damaged or missing.







2. Thoroughly clean surface using Betawipe spirit, fit finisher securing clips at positions marked and remove masking tape.







3. Fit and fully seat finisher to windshield.
4. To prevent sealant ingress into clips causing difficulty in subsequent removal of finisher, apply masking tape to back of finisher.







5. Fit lifting handles to glass and with assistance, correctly position windshield in body aperture and mark position with masking tape.







6. With assistance, remove windshield from vehicle and place on cloth covered bench.
7. Remove lifting handles and position glass outer face downwards.
8. Thoroughly clean glass edge and aperture flange with Betawipe spirit.
9. Apply glass primer to mating face of windshield.







10. Cut Betaseal nozzle to achieve a triangular section bead 8 mm wide by 10 mm high.







11. Using a suitable pneumatic application gun, apply a uniform bead of sealant to the glass edge commencing at bottom center and overlapping the ends approximately 100 mm.







12. Fit lifting handles and with assistance, carefully position windshield in aperture aligning glass with body markings and press firmly into place.







13. Remove lifting handles.
14. Remove tape marking windshield position.
15. Remove protective tape from leading edge of headlining.
16. Fit interior rear view mirror.
17. Fit sun visors.
18. Fit roof console.
19. Install LH and RH water deflectors and fit and tighten securing bolts.
20. Fit plenum chamber cover.
21. Fit Wiper arms.
22. If heated windshield is fitted, connect LH power supply cable to connector on secondary bulkhead.







23. If heated windshield is fitted, connect RH power supply cable to connector on secondary bulkhead.







24. Thoroughly clean exterior and interior of windshield.
25. Connect ground cable to battery terminal and fit battery cover.