Windshield Glass Using Cheese Wire

Windshield Glass Using Cheese Wire (76.81.40)

Special Service Tools
















Removal

1. Remove the interior mirror.
2. Remove both A- pillar trim panels.
3. Remove both sun visors.
4. Remove the overhead console.

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

Disconnect the heated windshield electrical connector.







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

Apply protective tape to the heated windshield electrical harness.







7. Remove the A- pillar windshield moulding.







8. Remove the cowl vent screen.

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

Remove both cowl vent screen finish panels.







10. Apply protective tape around windshield glass aperture to protect paintwork.







11. Apply suitable protective tape around leading edge of headlining.







12. Place a suitable protective sheet over fascia and place a protecting board over sheet
13. Prepare cheese wire and cutting handle.
- Position cutting handle central tube fully upwards in handle.
- Cut a suitable length of cheese wire and pass one end through handle tube and locating aperture.
- Move cutting handle central tube downwards to secure cheese wire.

14. Using a suitable long bladed tool, penetrate Betaseal approximately 150 mm from the top of one A pillar.







15. Remove tool, pass free end cheese wire through penetration and install second cutting handle.







16. CAUTION: When cutting, do not allow cheese wire to contact edge of windshield glass as this will crack the windshield glass.

With assistance and exercising care at the corners to avoid damaging paintwork, cut around windshield glass commencing downwards and along the bottom.







17. With assistance and exercising care, remove the windshield glass.
1. Attach lifting handles to windshield glass.
2. Remove the windshield glass.







18. Remove lifting handles from windshield glass.
19. Remove cheese wire cutter from windshield glass aperture, remove cutting handles and discard cheese wire.

Installation

1. WARNING:
- If the windshield glass is being installed at a temperature of 23 degrees (Centigrade), 73 degrees (Farenheit) 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 (Centigrade), 23 degrees (Farenheit) 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 (Centigrade), 11 degrees (Farenheit) 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 (Centigrade), 41 degrees (Farenheit) 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.
- Make sure the windshield glass does not move out of position in the windshield glass aperture.

NOTE: If the original windshield glass is to be installed remove the residual adhesive from windshield glass mating surface using the special tool.

Using the special tool, remove any residual adhesive from the body.







2. Thoroughly clean windshield glass surface using Betawipe spirit.







3. Apply primer to mating face of windshield glass.







4. Cut Betaseal nozzle to achieve a triangular section bead 8 mm ( 0.32 in) wide by 10 mm (0.4 in) high.







5. Using a suitable pneumatic application gun, apply a uniform bead of adhesive to the windshield glass edge commencing at bottom center and overlapping the ends approximately 14 mm (0.56 in).







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

With assistance carefully install windshield glass into the aperture. Aligning the windshield glass with the body markings and press firmly into place.







7. Remove the lifting handles.

8. 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.







9. Remove protective tape from leading edge of headlining.







10. Remove the protective sheet and the protective board from the fascia.

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

Install both cowl vent screen finish panels.







12. Install the cowl vent screen.
13. Install both A-pillar windshield mouldings.







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

Reconnect the heated windshield electrical connector.







15. Install the overhead console.
16. Install both sunvisors.
17. Install both A-pillar trim panels.
18. Install the interior mirror.