Windshield Glass Using Cutting Tool

Windshield Glass Using Cutting Tool (76.81.01)

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 electrical connector 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. Dispense 20 ml of WK9L lubricant into the WK9 spray bottle, fill the spray bottle with water and mix.
14. Apply cutting lubricant to the lower windshield glass adhesive and approximately 150 mm (6 in) up the A-pillar.
15. Install the cutting tool blade BTB-WK1SC to the cutting tool BTB-WK10HD.
16. Using the special tool cut through the lower windshield glass adhesive and approximately 150 mm (6 in) up the A-pillar.







17. Apply cutting lubricant to both sides of the A-pillar glass adhesive.

18. 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 BTBWK10HD.

Set the cutting tool controller arm to 20 mm.







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

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







20. Apply cutting lubricant to the top of the windshield glass.
21. Apply protective tape to the top of the windshield glass.







22. NOTE: Start cutting from either corner into the centre and continue the cut all the way through to the other corner. DO NOT cut from each corner into the centre as the pressure on the centre of the windshield glass could cause breakage.

Using the special tool cut through the top of the windshield glass adhesive.







23. Using the special tool cut through the right-hand side A-pillar remaining adhesive.







24. Using the special tool cut through the left-hand side A-pillar remaining adhesive.







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







26. Remove lifting handles from the windshield glass.

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 the mating face of the body.







4. Cut adhesive 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 the 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 the 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 around the leading edge of the headlining.







10. Remove the protective sheet and the protective board from the fascia.
11. Install the lower A-pillar drainage channels.







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







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

Reconnect the heated windshield electrical connector.







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