Installing Windshields

Installing windshields

Special tools:
998 6030 998 6030

Preparations




Install the six spacers that maintain the distance of the windshield from the body flange.
Always use new spacers.
Dimension A = 80 mm.
Dimension B = 270 mm.
Dimension C = 270 mm.




Install suction pads 998 6030 998 6030.
Place the window on a stand.
Install the trim strip on the top edge.

PUR

Note! Always open a side window when replacing the windshield, otherwise the windshield may move when the door is closed.

When working with PUR on the body flange, see PUR on body flange .





Cleaner H
Clean the area on the window to which PUR adhesive is to be applied with cleaner-H (black cap).





Glass activator
Apply glass activator (yellow cap) to the area on the window to which PUR adhesive will be applied.





Glass primer
Apply glass primer (green cap) to the area on the window to which PUR adhesive will be applied.
Apply generously (although not so much that it runs).
Let the primer dry until the surface is matt.

PUR adhesive activator
Apply the PUR adhesive activator (blue cap) on the remaining PUR bead on the body flange.

2-K:
Load the gun with both cartridges and the mixing pipe.
Check whether the adhesive kit contains a blue nozzle.
Use the nozzle if there is one.




If there is not a nozzle:
Take out the unmodified (complete) nozzle.
Measure 55 mm up from the base: Cut off the nozzle.
Drill a 3 mm hole 36.5 mm from the tip.
Measure 8 mm from the tip.
Cut the nozzle.
This makes a nozzle which gives a PUR-bead with a height of 18 mm and a base of 8 mm.

Note! This height is only required for fully cleaned bodywork.If there is a PUR bead remaining on the flange: Increase the application speed to achieve a lower bead.

Attach the nozzle.
Apply adhesive to either the window or to the body flange.
Hold the gun at right angles.
Ensure that the bead is continuous, otherwise the join will not be watertight.

Installing windshields
Position the windshield.
Push against the lower edge of the windshield by hand so that it comes down to the lower spacers.
Place a few strips of masking tape on the windshield and part way over the roof to prevent the pane from sliding down during the curing process.
Press the upper trim strip towards the car body until properly secure.
Leak test!

Note! Allow the adhesive to cure so that the window does not change position before installing the components.

Installing components

Install:
- the mounting for the headlining at the A-post
- interior lighting
- the sun visor and brackets
- the roof trim according to Roof trim
- the rear view mirror according to The inner rear view mirror Rear View Mirror
- the cowl according to Plenum chamber Service and Repair.





Note! A warning decal must be placed on the new windshield to indicate that the car is equipped with both SRS and SIPS airbags.