Removal and Replacement

WINDSHIELD GLASS

Special Tool(s):

Special Tool(s)

Removal

WARNING: To prevent glass splinters from entering the eyes or cutting hands, wear safety glasses and heavy gloves when cutting the glass from the vehicle. Failure to follow these instructions may result in personal injury.

1. Remove the cowl grille.
2. Remove the interior rear view mirror.







3. Remove the instrument panel defroster opening grille.
1 Unclip the instrument panel defroster opening grille from the instrument panel.
2 Disconnect the electrical connectors.
3 Remove the instrument panel defroster opening grille.







4. Remove the windshield side garnish mouldings.
5. Remove the sun visors and sun visor clips.
6. Partially remove the front door weatherstrips.
7. Lower the front portion of the headliner.







8. NOTE: Lubricate the existing urethane adhesive with water to aid the special tool while cutting.

Using the special tool, cut the urethane adhesive from the windshield starting at the top center and work toward the bottom corners.







9. CAUTION: When inflating the special tool, be careful not to over-stress the windshield glass, as this will cause breakage.

Using the special tool, distance the windshield glass from the body.







10. Using the special tool, cut the remaining urethane adhesive and remove the windshield glass.
11. Using a soft brush or vacuum, remove any dirt or foreign material from the pinch weld area.

Installation

CAUTION:
- After installing a new urethane-installed glass, the vehicle should not be driven until the urethane adhesive has cured. The curing time for Essex 400-HV 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 temperature and humidity vary.) Inadequate curing of the urethane adhesive may adversely affect the strength of the urethane adhesive.
- Make sure urethanes and primers have not gone beyond the shelf life printed on the containers. Lids should be re-installed after use to maximize actual shelf life, which may be less than what is indicated once lids or seals are removed.

1. Dry fit the windshield glass. Make alignment marks on glass and sheet metal with tape or non-staining grease pencil.







2. CAUTION: Avoid scratching the pinch weld area.

Trim the remaining urethane adhesive on the pinch weld to within specification.

3. Use a wool applicator to apply urethane metal primer to any exposed metal on the pinch weld area. Allow 6 to 10 minutes to dry.
4. If reinstalling the original windshield glass, remove the excess urethane adhesive from the windshield glass.

5. NOTE: If the molding 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.

6. If installing a new windshield glass, clean the windshield glass with an alcohol-free based window cleaner to make sure the ceramic-coated area is clean.

7. NOTE: Wipe off the glass prep with a clean lint-free cloth immediately after each application because it flash dries.

If installing a new windshield glass, apply urethane glass prep twice around the surface to be urethaned.

8. If installing a new windshield glass, apply glass primer to the same area that was in the previous step. Allow five minutes to dry.







9. Cut the urethane adhesive applicator tip to specification.







10. Apply a bead of urethane adhesive to the pinch weld.
11. Install the windshield glass aligning it to the marks made previously.
12. After the glass is set, check for water leaks and add urethane adhesive where needed.
13. Position the front portion of the headliner.
14. Install the front door weatherstrips.
15. Install the sun visors and sun visor clips.







16. Install the windshield side garnish mouldings.







17. Install the instrument panel defroster opening grille
1 Position the instrument panel defroster opening grille.
2 Connect the electrical connectors.
3 Install the instrument panel defroster opening grille

18. Install the interior rear view mirror.
19. Install the cowl grille.
20. Install and adjust the wiper blade and mounting arms.