Windshield: Service and Repair
Windshield Glass
This is a "Trustmark Authoring Standards (TAS) Repair Procedure"
- TAS style procedures can be identified by steps that have no accompanying step text and the magenta color of the electrical connectors and fasteners such as nuts, bolts, clamps or clips.
- TAS removal and installation procedures use a sequence of color illustrations to indicate the order to be followed when removing/disassembling or installing/assembling a component.
- Many of the TAS procedures will have the installation information within the removal steps.
- The TAS color illustrations use a variety of symbols to indicate important details of the procedures. It is important to understand these symbols in order to properly used the TAS procedures.
Refer to How to Use TAS Procedures and TAS Symbol Glossary at Vehicle | Description and Operation for additional information on these TAS procedures.
For additional information, refer to How to Use TAS Procedures How to Use TAS Procedures
Removal
CAUTION: Always protect paintwork and glass when removing exterior components.
CAUTION: Always protect the interior components when removing body glass.
CAUTION: Lay the glass on felt covered supports. Do not stand on edge as this can cause chips which subsequently develop into cracks.
NOTE:
The cutting blades used in this procedure are from the standard BTB glass removal kit.
NOTE:
Some variation in the illustrations may occur, but the essential information is always correct.
For additional information, refer to Interior Rear View Mirror Interior Rear View Mirror
NOTE:
The procedure must be carried out on both sides.
For additional information, refer to A-Pillar Trim Panel Pillar Trim
For additional information, refer to Plenum Chamber Plenum Chamber
NOTE:
The procedure must be carried out on both sides.
NOTE:
Discard the retaining clips.
1 Make sure that the centre part of the clip is fully removed from the outer part of the clip. It is not possible to prevent the centre part of the clip falling into the body of the vehicle.
NOTE:
The procedure must be carried out on both sides.
2 Disconnect the heating element electrical connectors.
NOTE:
The procedure must be carried out on both sides.
WARNING: Wear safety goggles and protective gloves.
CAUTION: Protect the surrounding paintwork to avoid damage.
CAUTION: Protect the surrounding components.
NOTE:
Windshield glass shown removed for clarity.
Cut between points 3 and 4, use a WK1S blade, reverse cut with the flat side against the body.
Cut the bottom corner at points 3 and 4, use a WK1S blade.
Cut between points 4 and 1, use a WK24ZRS blade against the body and a WK11B controller arm set to 26mm cut depth.
Cut between points 3 and 2, use a WK24ZRS blade against the body and a WK11B controller arm set to 26mm cut depth.
Cut between points 5 and 6, use a WK24RS.
Cut between points 1 and 2, use a WK1S blade, reverse cut with the flat side against the windshield glass and a WK11B controller arm set to 26mm cut depth.
Cut the top corner at points 1 and 2, use a WK1S blade.
Cut any adhesive from the windshield to allow removal, use a WK1S blade.
WARNING: This step requires the aid of another technician.
Installation
CAUTION: Make sure that a Hi-modulus sealer (for example, Wurth Ultimate adhesive) is used when bonding the component to the vehicle.
CAUTION: Make sure that the mating faces are clean and free of foreign material.
Prepare the window glass, window glass flange and trimmed PU adhesive in accordance with the instructions included with the PU adhesive kit.
CAUTION: Touching the adhesive surface will impair rebonding.
Apply a continuous bead of sealant to the windshield glass.
WARNING: This step requires the aid of another technician.
CAUTION: Make sure that the component is correctly located on the locating dowels.
CAUTION: Make sure that equal pressure is applied to the full length of the component.
With assistance, install and align the windshield glass.
Lightly press the window glass to seat the sealer.
Secure the windshield glass in position using tape.
If the ambient temperature falls below 10 degrees C, apply warm air (25 degrees C) continuously for 15 minutes.
CAUTION: Make sure that no excess sealant residue is evident.
If water is used as a means for the leak check, then allow sealant to dry before testing.
Spray water around the windshield glass, mark any area that leaks. Dry the windshield glass and sealant before applying additional sealant.
NOTE:
The procedure must be carried out on both sides.
NOTE:
The procedure must be carried out on both sides.
1 Connect the heating element electrical connectors.
NOTE:
The procedure must be carried out on both sides.
For additional information, refer to Plenum Chamber Plenum Chamber
NOTE:
The procedure must be carried out on both sides.
For additional information, refer to A-Pillar Trim Panel Pillar Trim
For additional information, refer to Interior Rear View Mirror Interior Rear View Mirror