Windshield Glass

REMOVAL
1. Disconnect the battery ground cable.







2. Heat the adhesive if necessary.

NOTE: Should the ambient temperature fall below 10°C heat the cartridges for approximately 15 minutes by placing them on a warm radiator, or by using a hot air gun set at approximately 25°C.

3. Remove the grille assembly, cowl top vent panel.







4. Remove the A-pillar windshield trims.







5. Remove the 12 A-pillar trim retaining clips.







6. Remove the windshield top weatherseal.







7. Detach the door weatherstrip
8. Remove the A-pillar trim.







9. Drop the headliner near the windshield.

NOTE: Place a small block of suitable material between the headliner and roof to act as a spacer.







10. Cut around the windshield using the Oscillating Cutter No 107-R1511 with a 28 mm hook blade.

WARNING: Wear gloves and eye protection when working with the glass cutting tool as the cutting operation may produce splinters. When using the cutter wear ear protection. Failure to follow these instructions will result in personal injury.







11. Cut the bottom edge of the windshield using the Oscillating Cutter No. 107-R1511 fitted with a 60 mm hook blade.







12. Use Interior Auto Glass Cut-Out Knife No. 164-R2450 or equivalent to cut out the PU adhesive, using the 4 in cutter blade on the top and the side edges of the windshield.

WARNING: Wear gloves and eye protection when working with the glass cutting tool as the cutting operation may produce splinters. When using the cutter wear ear protection. Failure to follow these instructions will result in personal injury.

NOTE:
^ Lubricate the PU adhesive where it meets the glass with EC7784 lubricant or equivalent (10:1 ratio of water to soap) to aid Interior Auto Glass Cut-Out Knife Kit, when cutting the PU adhesive.
^ If a heated windshield is to be reinstalled, ensure the cutter blade is kept low when cutting in the area of the heated windshield connectors.

13. Cut the bottom edge of the windshield using Interior Auto Glass Cut-Out Knife No. 164-R2450 fitted with the 8 in cutter blade.
14. With the aid of another technician, using suction cups, remove the windshield.







15. Drill out the rivets and remove the locator blocks.

INSTALLATION







1. Remove the excess PU adhesive from the aperture using a utility knife.
^ Carefully trim the remaining PU adhesive from the windshield opening to leave approximately 1 mm of trimmed PU adhered to the bodywork.
^ Check the pinch weld sealing area for damaged sheet metal, rust or foreign objects which may have caused, or may cause, glass breakage.

CAUTION: Avoid touching the trimmed surface as this will inhibit the new adhesive from bonding.

2. If the original windshield is to be reinstalled, remove the excess PU adhesive from the glass as described in the previous step.







3. Fit new locator blocks.

NOTE: Use a heavy duty riveter to install new rivets.







4. Using a hot air gun, apply warm air (25°C) to the windshield opening and glass bond line to remove all traces of moisture.

NOTE: To ensure that the PU adhesive cures, it is essential that all bonding surfaces are free of moisture.

5. Prepare the glass, windshield opening and trimmed PU adhesive in accordance with the instructions supplied with the adhesive kit.







6. Apply the PU adhesive in a continuous bead of between 8 and 10 mm height to the windshield flange along the bond line.

NOTE:
^ Discard the first 10 cm (4 in) of PU adhesive as this may have a reduced working time.
^ To avoid water leaks, any breakage in the continuous bead should be overlapped by 20 mm (0.75 in).







7. Install the windshield.
^ With the aid of another technician, use suction cups to carefully lift the glass and align it over the window flange.
^ Firmly and evenly press into position.







8. Should the ambient temperature fall below 10°C, use a hot air gun at a distance of approximately 5 cm from the substrate and apply warm air (25°C) continuously for 15 minutes (inside or outside the vehicle).







9. Remove the spacer and install the headliner.
10. Install the A-pillar trim panels.







11. Install the door weatherstrip.







12. Install the windshield top weather seal.







13. Install the 12 A-pillar trim retaining clips and install the A-pillar windshield trims.
14. Install the cowl top vent panel.
15. Connect the battery ground cable.