Windshield: Service and Repair

Windshield Glass

Service Repair No - 76.81.01

Removal

NOTE: The following equipment is required: Cutting wire and handles. Reciprocating cutting knife. Glazing knife. Windshield glass replacement kit. Sealant applicator. Suction cups. Felt covered table or a felt covered glazing support stand.

1. Remove the roof mouldings.
2. Remove the windshield glass mouldings.
3. Remove the cowl panel grille.
4. Remove the interior rear view mirror.
5. Remove the A-pillar trim panels.
6. Disconnect the 2 electrical connectors from the heated windshield glass element.







7. Apply protection to the exterior paintwork, adjacent to the windshield glass.
8. Apply masking tape to the defroster ducts.
9. Apply protection to the instrument panel and interior of the vehicle.
10. Remove the windshield glass upper moulding.







11. Using a flat blade cutting tool and working from the outside, cut through the windshield glass sealant securing both sides and the upper section.
^ Use of a reciprocating flat blade glazing knife is permissible.
^ If necessary use a cutting wire to cut through any remaining windshield glass sealant securing the sides and the upper section.







12. Working from the inside and using a glazing knife, cut through the windshield glass sealant securing the lower section.
^ Use of a reciprocating flat blade glazing knife is permissible







13. CAUTION: Lay the glass on felt covered supports. Do not stand on edge as this can cause chips which subsequently develop into cracks.

With assistance, remove the windshield glass.
^ Use suction cups to aid removal.

14. Remove the 4 windshield glass support blocks from the vehicle body.







15. Remove the windshield glass sealant from the vehicle body.
^ Make sure when the sealant has been removed that the finished surface is clean and smooth.

16. Remove the windshield glass sealant from the windshield glass.
^ Make sure when the sealant has been removed, that the surface is clean and smooth and without damage to the obscuration band.

Installation

1. Install the windshield glass upper moulding.
2. Install the windshield glass support blocks to the vehicle body.
3. With assistance, install the windshield glass and centralize in the vehicle body aperture.
4. Use masking tape to establish reference marks and to aid as an alignment guide.







5. With assistance, remove the windshield glass.
6. Using the recommended solvent, clean the mating faces of the vehicle body windshield glass aperture and windshield glass.
7. Apply etch primer to the vehicle body windshield glass aperture.
8. Apply primer over the previously applied etch primer.
9. Apply glass primer to the sealant mating face of the windshield glass and allow to cure.
10. Apply activator over the old sealant on the vehicle body windshield glass aperture and allow to cure.
11. Install the pre-cut nozzle to sealant cartridge and remove the lid and shake out the crystals, followed installing the cartridge to the applicator tool.
12. Apply a continuous bead of sealant to the windshield glass as shown.







13. With assistance, install and align the windshield glass.
^ Lightly press the windshield glass to seat the sealant.

14. Remove the masking tape and exterior paintwork protection.
15. Test the windshield glass sealant for leaks.
^ 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.

16. Connect the heated windshield glass element, electrical connectors.
17. Install the A-pillar trim panels.
18. Install the interior rear view mirror.
19. Install the cowl panel grille.
20. Install the windshield glass mouldings.
21. Install the roof mouldings.