Windshield: Service and Repair
WINDSHIELD GLASSSpecial Tool(s):
SPECIAL TOOL(S)
REMOVAL
1. Remove the cowl panel grille.
2. Remove the windshield side exterior moulding.
3. Remove the interior mirror.
4. Remove the rain sensor module (if equipped).
5. Remove the windshield interior trim as necessary.
6. Lower the front portion of the headliner.
7. Remove the windshield.
Item 1: Windshield Glass Removal Note
1. Using a soft brush or vacuum, remove dirt and foreign material from the pinch weld.
2. CAUTION:
- Cover the instrument panel in order to prevent possible damage.
- Care must be used to avoid scratching the pinch weld.
NOTE:
- Lubricate the existing urethane adhesive with water to aid the special tool while cutting.
- When cutting foam inside, first cut foam dam to access urethane adhesive.
Using the special tool, starting at the top center of the windshield glass, cut the urethane adhesive away from the glass and work down the sides.
3. Using the special tool, distance the windshield from the body.
4. Remove the dual lock windshield glass stops from the sheet metal frame.
5. Using the special tool, cut the remaining urethane adhesive and remove the windshield.
6. Using a soft brush or vacuum, remove dirt and foreign material from the pinch weld.
INSTALLATION
1. To install, reverse the removal procedure.
Item 1: Windshield Glass Installation Note
CAUTION: After installing the new windshield glass, the vehicle should not be driven until the urethane adhesive has cured. The curing time at temperatures above 13°C (55°F) and relative humidity above 50% is 12-24 hours. (Refer to the Essex drive away chart for the cure times as the temperatures and humidity vary). Inadequate curing of the urethane adhesive may adversely affect the strength of the urethane adhesive bond.
1. Dry fit the new windshield glass to the existing urethane bed on the body pinch weld. Align the windshield in the opening for uniform fit and adjust setting blocks as needed for the best fit.
2. Use tape or non-permanent marking pencil to make alignment marks on the windshield (preferably at the setting blocks), and the body to aid in the installation alignment of the new windshield.
3. After alignment, remove the windshield glass and molding assemblies from the vehicle and place on a stable work surface.
4. CAUTION: Care must be taken to avoid scratching the pinch weld.
Trim the remaining urethane adhesive on the pinch weld. The urethane must be smooth and free of cuts and contamination after trimming. Avoid touching the urethane surface after preparation.
5. CAUTION: All rust found on the pinch weld must be removed and the pinch weld restored to OEM specifications. If surface rust is found, remove completely down to clean, bare metal. Prime pinch weld metal with an OEM recommended curing automotive paint primer and allow to cure. If rust has penetrated through the pinch weld metal, repair the pinch weld sheet metal at a body shop before proceeding.
Check the pinch weld for damaged sheet metal, raised sheet metal at the spot welds, rust or foreign material that may cause glass breakage. Clean or repair surface as necessary.
6. Use a wool applicator to apply urethane metal primer to any exposed metal on the pinch weld. Allow six to ten minutes to dry.
7. Clean the inside of the glass surface with an alcohol-free cleaner to make sure the ceramic-coated area is clean.
8. NOTE: If the moulding is already on the windshield glass, proceed to the next step.
Align the "V" notch in the ceramic paint and windshield outside molding at top center. Fully seat the windshield outside molding along the top edge of the windshield glass and along the sides and bottom edges of the windshield glass.
9. Remove the dual lock windshield glass stop adhesive backing.
10. Apply urethane glass primer to the same area that was prepped in the previous step. Allow five minutes to dry.
11. Cut the urethane adhesive applicator tip to specification.
12. CAUTION: If the vehicle is to be driven within 24 hours of urethane adhesive application, urethane adhesive must be used due to its one-hour cure time.
Apply a bead of urethane adhesive to the pinch weld.
13. CAUTION: Open the windows to prevent the windshield glass from being pushed out by air pressure if a door is closed.
Install the windshield glass on the pinch weld. Align the windshield glass to the body using the alignment marks while pushing downward to set the stops.
14. Inspect the windshield glass installation for air or water leaks and add urethane adhesive where needed.
15. Place two strips of duct tape onto the windshield glass and secure it to the roof panel. This will help avoid misalignment while the urethane cures.