Windshield: Service and Repair

REMOVAL
1. Disconnect the battery ground cable.







2. Heat the Polyurethane (PU) adhesive if necessary.

NOTE: Should the ambient temperature fall below 10°C heat the cartridges for approximately 5 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. l07-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 MAY RESULT IN PERSONAL INJURY.

NOTE: If a heated windshield is to be reinstalled, make sure the cutter blade is kept low when cutting in the area of the heated windshield connectors.







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 MAY 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, make sure 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, use suction cups to remove the windshield glass.







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

INSTALLATION







1. Remove the excess PU adhesive from the opening flange.

^ Carefully trim the remaining PU adhesive from the windshield opening to leave approximately 1 mm of trimmed PU adhered to the bodywork.

CAUTION:
^ During the curing period of the PU adhesive, the door windows must be left open to avoid a build up of pressure when the doors are opened and closed.
^ Avoid touching the trimmed surface as this will inhibit the new adhesive from bonding.


2. Check the pinch weld sealing area for damaged sheet metal. rust or foreign objects which may have caused, or may cause, glass breakage.







3. Using a Hot Air Gun, apply warm air (25°C) to the windshield opening and glass bond line to remove all traces of moisture.

CAUTION: To make sure that the PU adhesive cures, it is essential that all bonding surfaces are free of moisture.

4. Prepare the glass, windshield opening and trimmed PU adhesive in accordance with the instructions supplied with the adhesive kit.
5. If the original windshield is to be reinstalled, remove the excess PU adhesive from the glass as described in the previous step.







6. Install the windshield weatherstrip.







7. Fit new locator blocks.

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







8. NOTE: Discard the first 100 mm (4 in) of PU adhesive as this may have a reduced working time.







9. With the aid of another technician, use suction cups to install the windshield glass.

NOTE: Firmly and evenly press in position.







10. Should the ambient temperature fall below 10°C, use a hot air gun at a distance of approximately 50 mm from the substrate and apply warm air (25°C) continuously for 15 minutes (inside or outside the vehicle).







11. Remove the spacer and install the headliner.
12. Install the A-pillar trim panels.







13. Install the door weatherstrip.







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