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 15 minutes by placing them on a warm radiator, or by using a hot air gun set at approximately 25°C.

3. Raise the hood.







4. Remove the windshield wipers.







5. Remove the cowl grille panels.
1. Remove the screw cover.
2. Remove the screw.
3. Release the clips.
6. Lower the hood.







7. Remove the A-pillar trim panels.
1. Detach the clip at the B-pillar.
2. Detach the locating dowel at the base of the A-pillar.







8. Detach the interior lamp.







9. Remove the interior lamp.
^ Disconnect the electrical connectors.







10. Remove the interior lamp bezel.
^ Remove the screws.







11. Remove the interior mirror.







12. Remove the sun visors.
^ Remove the screws.







13. Remove the sun visor clip.
1. Open the cover.
2. Remove the screw.







14. Detach the front of the headliner.
^ Place two blocks of suitable material between the headliner and the roof panel to act as spacers.







15. From inside the vehicle cut the PU adhesive at the given maximum depths. Use the recommended blades, following the proprietary tool manufacturers instructions.
1. 23 mm.
2. 75 mm.
3. 160 mm.

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 PROTECTORS. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.

CAUTION: Make sure the cutting blades are changed where the cutting depth changes to avoid damage to the body and trim panels.







16. With the aid of another technician, use suction cups to remove the windshield glass.
17. Remove the windshield glass weatherstrip.

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 opening flange.

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 bonding of the new adhesive.

2. Check the pinch weld sealing area for damaged sheet metal, rust or foreign material 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. Apply a thin continuous bead of PU adhesive to the edge of the windshield glass.

NOTE:
^ Discard the first 100 mm of PU adhesive as this may have a reduced working time.
^ To avoid water leaks, any breakage in the continuous bead should he overlapped by 20 mm.

6. Install the windshield glass weatherstrip.







7. Apply the PU adhesive in a continuous bead of between 11 and 15 mm height to the windshield opening flange along the bond line.

NOTE:
^ Discard the first 100 mm 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.







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

NOTE: Firmly and evenly press in position.







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







10. Install the interior mirror.







11. Install the headliner.
^ Remove the spacers.







12. Install the sun visor clip.
1. Install the screw.
2. Close the cover.







13. Install the sun visors.







14. Install the interior lamp bezel.
^ Install the screws.







15. Connect the interior lamp electrical connectors.







16. Install the interior lamp.







17. Install the A-pillar trim panels.
1. Locate the dowel at the base of the A-pillar.
2. Locate the clip at the B-pillar.
18. Raise the hood.







19. Install the cowl grille panels.
1. Locate the clips.
2. Install the screw.
3. Install the screw cover.







20. Install the windshield wipers.
21. Lower the hood.
22. Connect the battery ground cable.