Windshield: Service and Repair
SPECIAL TOOL(S)
REMOVAL
WARNING: TO PREVENT GLASS SPLINTERS FROM ENTERING THE EYES OR CUTTING THE HANDS, WEAR SAFETY GLASSES AND HEAVY GLOVES WHEN CUTTING THE GLASS FROM THE VEHICLE.
1. Remove the cowl grille.
2. Remove the interior rear view mirror.
3. Position the LH and RH front door weatherstrips aside.
4. Remove the LH and RH windshield side garnish mouldings.
5. Remove the eight screws, the LH and RH sun visors and the two sun visor clips.
6. If equipped, remove the dome lamp assembly.
7. Partially lower the headliner near the windshield opening and block with suitable material.
8. Using a soft brush or vacuum, remove any dirt or foreign material from the pinch weld.
9. Using the special tool, place the flat side of the knife against the windshield glass. Start at the top center of the windshield glass and work out and down the pillars to the lower corners.
NOTE: Lubricate the urethane adhesive with water to aid the special tool in cutting the urethane.
10. Install the special tool into the top of the windshield glass and inflate. Cut the urethane adhesive from corner to corner along the bottom of the windshield glass.
11. Remove the windshield glass.
12. Using a soft brush or vacuum, remove any dirt or foreign material from the pinch weld.
INSTALLATION
CAUTION: When installing urethane installed glass parts, the vehicle must not be driven until the urethane has cured. At temperatures above 21°C (70°F) and relative humidities above 50%, adequate cure time is typically 24 hours. (Refer to the Essex drive away chart for the cure times as the temperatures and humidity vary). Inadequate or incorrect curing can adversely affect the retention of the windshield.
1. Dry fit the windshield glass to the existing urethane adhesive bead on the body pinch weld. Align the windshield glass in the opening for a uniform fit.
2. Use a non-permanent pencil to make alignment marks on the windshield glass at the setting blocks and the body to aid in the installation alignment of the windshield glass.
3. Remove the windshield glass.
4. Trim the remaining urethane adhesive on the pinch weld. The urethane adhesive must be smooth and free of cuts and contamination after trimming. Avoid touching the urethane surface after preparation.
NOTE: Avoid scratching the pinch weld.
5. Apply urethane metal primer to minor scratches or exposed metal on the pinch weld caused during removal. Do not apply primer to the existing urethane adhesive.
6. If installing the original windshield glass, remove the excess urethane adhesive.
7. Clean the inside of the windshield glass surface with a non-alcohol based glass cleaner.
8. If installing a new windshield glass, apply urethane glass prep to the area to be urethaned.
CAUTION: Wipe off the urethane glass prep immediately after each application because it flash dries.
9. If installing a new windshield glass, apply urethane glass primer to the same area in the previous step. Allow five to seven minutes to dry.
10. Cut the urethane adhesive applicator tip to specification.
11. Apply urethane adhesive on top of the existing trimmed urethane adhesive bead on the pinch weld. Make sure that all gaps in the urethane adhesive are smoothed into one continuous bead.
CAUTION: If vehicle is to driven within 24 hours of urethane application, urethane adhesive Essex U-216 must be used due to its one-hour cure time.
12. Install the windshield glass on the vehicle aligning it with the markings made previously.
13. Check the windshield glass installation for air or water leaks through the urethane adhesive seal.
14. Position the headliner.
15. If equipped, install the dome lamp assembly.
16. Install the two sun visor clips, the LH and RH sun visors, and the eight screws.
17. Install the RH and LH windshield side garnish mouldings.
NOTE: When installing the windshield side garnish mouldings, be sure the alignment tabs are positioned correctly.
18. Install the LH and RH front door weatherstrips.
19. Install the interior rear view mirror.
20. Install the cowl grille.