Windshield Removal & Installation Information

Windshield Removal:


1. Remove the door sealing strips and padded trim from the "A" pillars.
2. Remove the grab handle, the sun visors and brackets, the rear-view mirror and the cover for the overhead panel, to enable the headliner to be pulled down and out of the way.

3. Remove the speaker grilles and the top of the instrument panel.


4. Place covers over the speakers to prevent dirt from getting into the diaphragms.

Cover seats and dash opening with a tarp to keep glass debris out.

5. Remove the windshield wipers.



6. Remove the cover pieces, mouldings and moulding retaining strips from the windshield.



7. Apply tape to all the paintwork surrounding the glass. Position the tape with its edge along the outer curved part of the frame.



8. If so equipped, unscrew and bend back the metal brackets.

Found only from H1014800-.



9. Cut out the glass (Fein Power Cutter shown, See S.I. 01/87-918) starting with the 24 mm blade.

Start up the cutter and begin by inserting the blade through the bead of the adhesive in one of the bottom corners.


Note: Keep the blade sharp with the sharpening stone that is supplied!



10. Working in a clockwise direction, cut all the way around the glass. If the glass does not come free, cut again using the 36 mm blade.




11. Attach the suction cups and lift out the glass.



12. Attach the suctions cups to the new windshield. Place on a suitable stand with the inside of the glass facing upwards.



13. Using the trimming knife supplied with the cutter, trim the bead of adhesive on the window frame flange to a maximum thickness of 2 mm.

Do not remove all of the original adhesive. This provides a good base for the fresh adhesive.

Remove all tape protecting the paintwork.



Windshield Installation:


1. Thorougly clean the edge of the glass and the metal flange of the car using the cleaning solution from Adhesive Kit 30-07-119.


NOTE: Do not allow the cleaner to dry naturally as this may leave traces of grease. Always use clean, lint-free rags, refolding them frequently and using a clean one for each surface.


The car must be setting on level ground and on all four wheels during the installation.



2. Apply primer to the edge of the glass and to the metal flange of the car. Keep the application of primer at least 1/8" away from the edge of the black painted strip of the glass.

The primer should be generously applied to the paintwork right up to the tape line applied during glass removal but away from any exposed paintwork (see shaded area in the drawing).


NOTE: Any primer getting on exposed paint must be removed immediately otherwise the paint may be damaged.



3. Fit the moulding retaining strips from the windshield kit to the edge of the glass.

Do not hammer the strip onto the glass. Simply apply enough pressure to the strip so that its sealant adheres to the glass.

Fit the moulding. Later glass (5.5 mm thick), uses a one piece moulding strip. Fit the one piece moulding by starting from the midway point on the bottom of the glass, working left and right. Work moulding carefully to take up excess. Make sure that the joint in the rubber comes midway across the bottom of the glass.






4 The applicator tip must be adjusted to form the shape to the right. the bead of adhesive that is applied must be this triangular shape to ensure a good seal and to prevent excess adhesive from being applied.

Application gun pressure may be varied to aid in achieving the desired shape.

Heat the applicator tip in hot water and then form the tip.



5. Apply a bead of adhesive to the metal flange and adjust your pressure to obtain the shape shown at the right.

Always hold the applicator perpendicular to the surface.

Check that there are no cavities or openings in the adhesive.



6. Position the two rubber spacers along the bottom of the windshield frame.

Place the windshield into the frame opening and press into place so it is flush with the surrounding paintwork.

Install a soft belt across the glass (over the suction cups) and secure at the "A" pillars.


NOTE: Do not overtighten any belt that is applied across the windshield otherwise a crack may result.


7. The glass can now be adjusted into position using the suction cups and a belt running across the windshield and around the "A" pillars.