Windshield: Service and Repair
Windscreen
Service Repair No - 76.81.01
The following equipment is required: Cutting wire and handles, Windscreen repair kit, Sealer applicator gun and Suction cups.
WARNING:
^ Wear protective gloves when handling glass, solvents and primers.
^ Wear suitable eye protection when removing and refitting glass.
Remove
1. Remove air intake panel.
2. Remove sun visors and sun visor retaining clips.
3. Remove 'A' post upper trim casings.
4. Remove retaining stud from front of headlining.
5. Remove interior mirror.
6. Fit protection to bonnet and areas around screen.
7. Cover heater ducts with masking tape.
8. Cover interior of vehicle with protective sheet.
9. Make knife cut in sealant at bottom of 'A' post.
10. Insert cutting wire through previously made knife cut and fit handles as shown, with approximately 200 mm of wire between handles.
11. Using suitable cutting wire, with assistance if required, carefully cut sealer. Ensure that glass is retained as last sealant is cut.
If multi-strand cutting wire is used, a sawing action can be used to cut through heavy sealant deposits around corners.
CAUTION: Use of a sawing action may overheat and break single strand wire.
12. Attach suction cups and use assistance to remove glass from body.
CAUTION: Lay glass on felt covered supports. Do not stand on edge. Any chipping of glass edge may develop into cracks.
13. Collect screen support blocks.
Refit
1. Carefully remove excess sealer from body leaving a smooth surface.
2. Use a vacuum cleaner to clear away any waste.
3. Original glass: Carefully cut back old sealer to obtain a smooth surface without damaging obscuration band on glass.
4. Fit spacer blocks to body.
5. With assistance, locate screen to body.
6. Apply masking tape reference marks to aid fitment.
7. With assistance, remove screen and place aside.
8. Clean frame and edge of screen with solvent.
CAUTION: Do not touch cleaned or primed surfaces with fingers.
9. Apply etch primer to any bare metal on frame.
10. Apply bonding agent to screen and allow to cure.
11. Apply primer over etch primer on frame.
12. Apply activator over old sealer on frame.
13. Allow activator to cure.
14. Fit pre-cut nozzle to sealer cartridge, remove lid and shake out crystals, and install in applicator gun.
Nozzle will need modification to achieve required bead section.
15. Apply a continuous bead of sealer around edge of frame as shown.
16. Check for breaks and air bubbles in sealer.
17. With assistance, lift screen into place and align to screen supports and tape. Raise screen up to roof on ratchet support blocks. Lightly press glass to fully seat sealer.
18. Remove protective covers and tape.
19. Test sealer for leaks, apply additional sealer if necessary. If water is used, allow sealer to dry before testing. Spray water around glass and check for leaks. Mark any area that leaks. Dry glass and sealer then apply additional sealer.
20. Fit 'A' post upper trim casings.
21. Fit headlining retaining stud.
22. Fit sun visor retaining clips and sun visors.
23. Fit interior mirror.
24. Fit air intake panel.
CAUTION: A curing time of 6 hours is desirable, during this time leave a window open and do not slam the doors. If the car must be used, drive slowly.