Windshield: Service and Repair

REMOVAL

All vehicles







1. Remove the Polyurethane (PU) adhesive cap and heat the PU adhesive for a minimum of 30 minutes.
2. Raise the hood.
3. Disconnect the battery ground cable.







4. Remove the windshield wiper arms.

NOTE: Make sure that the windshield wiper motor is in the park position.







5. Remove the cowl 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.

Vehicles with roof opening panel
8. Remove the overhead console.

Vehicles without roof opening panel







9. Detach the interior lamp from the overhead console.







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

All vehicles







11. Remove the interior mirror.







12. Remove the sun visors.







13. Remove the sun visor retaining clips.
1. Open the covers.
2. Remove the screws.







14. Detach the leading edge of the headliner and place two blocks of suitable material between the headliner and the roof opening to act as spacers.







15. From inside the vehicle, using a suitable direct glazing cutter, cut the PU adhesive to the given maximum depths.
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.

NOTE: Some resistance may be encountered when cutting through the glass locating pegs in the lower corners of the glass.







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

INSTALLATION

All vehicles
1. Carefully remove the remaining part of the glass locating pegs from the windshield glass flange.







2. Carefully trim the remaining PU adhesive from the windshield glass flange to leave approximately 1 mm of trimmed PU adhesive adhered to the flange.

CAUTION: Do not touch the adhesive surface as re-bonding will be impaired.

3. Check the windshield glass flange for damaged sheet metal, rust or foreign material which may have caused, or may cause, glass breakage.
4. Using a hot air gun, apply warm air (25°C) to the windshield glass flange 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.

5. Prepare the glass, windshield glass flange 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 in height to the windshield glass 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 must be overlapped by 20 mm.

7. Install the windshield glass weatherstrip.







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

^ Press firmly and evenly into position.
9. Using suitable tape, secure the windshield glass in the correct position until the PU adhesive has cured.

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.







10. If the ambient temperature falls below 10°C, use a hot air gun and apply warm air (25°C) continuously for 15 minutes (inside or outside the vehicle).







11. Remove the spacers and attach the leading edge of the headliner to the roof panel.







12. Install the sun visor retaining clips.
1. Install the screws.
2. Close the covers.







13. Install the sun visors.







14. Install the interior mirror.

Vehicles without roof opening panel







15. Connect the interior lamp electrical connectors.







16. Install the interior lamp.

Vehicles with roof opening panel
17. Install the overhead console.

All vehicles
18. Install the A-pillar trim panels.
19. Raise the hood.







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







21. Install the windshield wiper arms.
22. Connect the battery ground cable.
23. Lower the hood.