Windshield Glass Using Cutting Tool

Windshield Glass Using Cutting Tool (76.81.01)

Special Service Tools




























Removal

1. Remove the sun visors.
2. Remove the cowl vent screen.
3. Remove the interior mirror.

4. NOTE: Left-hand shown, right-hand similar.

Disconnect the heated windshield glass electrical connectors.







5. Remove the A-pillar exterior trim.







6. Apply suitable protective tape around the windshield glass aperture to protect the paintwork.







7. Place a suitable protective sheet over the fascia and place a protective board over the sheet.
8. Apply suitable protective tape to the leading inner edge of the roof panel.







9. Dispense 20 ml of WK9L lubricant into the WK9 spray bottle, fill the spray bottle with water and mix.
10. Apply cutting lubricant to the lower windshield glass adhesive and approximately 150 mm (5.9 in) up the A-pillar.
11. Install the cutting tool blade BTB-WK1SC to the cutting tool BTB-WK10HD.

12. NOTE: Right-hand shown, left-hand similar.

Using the cutting tool, cut through the lower windshield glass adhesive and approximately 150 mm (5.9 in) up the A-pillar.







13. Apply cutting lubricant to both sides of the inner A-pillar windshield glass adhesive.

14. NOTE: Remove the cutting tool blade BTB-WK1SC from the cutting tool BTB-WK10HD.

Install the cutting tool side cutting blade BTB-WK24ZS and the cutting tool controller arm BTB-WK11B to the cutting tool BTB-WK10HD.
- Set the cutting tool controller arm to 20 mm.







15. NOTE:
- Right-hand shown, left-hand similar.
- Start cutting the windshield glass adhesive from the top of the A-pillar downwards.

Using the cutting tool, cut through A-pillar windshield glass adhesive.







16. Apply cutting lubricant to the top of the inner windshield glass adhesive.
17. Apply suitable protective tape to the top of the windshield glass.







18. NOTE: Start cutting from either corner into the center and continue the cut all the way through to the other corner. Do not cut from each corner into the center of the windshield glass as the pressure on the center of the windshield glass could cause breakage.

Using the cutting tool, cut through the top of the inner windshield glass adhesive.







19. NOTE: Right-hand shown, left-hand similar.

Using the special tool cut through any remaining windshield glass adhesive on the A-pillars.







20. With assistance remove the windshield glass.
- Attach the lifting handles to the windshield glass.







21. Remove the lifting handles from the windshield glass.

22. NOTE: To aid bonding of a new windshield glass, make sure at least 1 mm (0.3 in) of residual adhesive remains on the body flange.

Using the special tool remove the residual adhesive from the body flange.







Installation

1. Make sure the new windshield glass surface is clean using Betawipe spirit.







2. Apply glass primer to mating face of the windshield glass.







3. Apply glass primer to the mating face of the body flange.







4. Cut the adhesive nozzle to achieve a triangular section bead 8 mm (0.31in) wide by 13 mm (0.51 in) high.







5. NOTE: Apply windshield adhesive WSS-M2G379-A6A or equivalent meeting Jaguar specification around the windshield glass edge.

Using a suitable pneumatic application gun, apply a uniform bead of adhesive to the windshield glass edge commencing at the bottom center and overlapping the ends approximately 14 mm (0.55 in).







6. WARNING:
- If the windshield glass is being installed at 23 degrees C (73 degrees F) or above make sure the vehicle is not driven for at least 1 hour after installation.
- If the windshield glass is being installed at a temperature of 11 degrees C (52 degrees F) to 23 degrees C (73 degrees F) make sure the vehicle is not driven for at least 1.5 hours after installation.
- If the windshield glass is being installed at a temperature of 5 degrees C (41 degrees F) to 11 degrees C (52 degrees F) make sure the vehicle is not driven for at least 2 hours after installation.
- If the windshield glass is being installed at a temperature below 5 degrees C (41 degrees F) use heat and make sure the windshield glass adhesive has set before the vehicle is driven.

CAUTION: When installing the windshield glass, do not strike it in any way as this will crack the glass.

Install the lifting handles and with assistance, carefully position the windshield glass in the aperture.
- Align the windshield glass and press firmly into place.
- Remove the lifting handles.







7. CAUTION: Make sure the windshield glass does not move out of position in the windshield glass aperture.

Apply suitable protective tape to the top of the windshield glass.







8. Remove the protective tape from the inner leading edge of the roof panel.







9. Remove the protective sheet and the protective board from the fascia.
10. Remove the protective tape from the windshield glass aperture.







11. NOTE: Left-hand shown, right-hand similar.

Connect the the heated windshield glass electrical connectors.







12. Install the A-pillar exterior trim.







13. Install the interior mirror.
14. Install the cowl vent screen.
15. Install the sun visors.

16. CAUTION: Make sure the windshield glass adhesive is set before removing the protective tape.

Remove the protective tape from the top of the windshield glass.