Windshield: Service and Repair

Windshield Replacement

Special Tools
- BO-641Suction Holder
- BO-46974 Glass Removal System

For equivalent regional tools, refer to Special Tools.

WARNING: Approved safety glasses and gloves should be worn when performing this procedure to reduce the chance of personal injury.

NOTE: The following document describes the procedure for removing the windshield using BO-46974 glass removal system. As a supplement to the existing video VT 54, concise steps will be shown for removing the windshield without destroying it. With the introduction of BO-46974 glass removal system, the conventional glass removing methods are no longer used.

Position the vehicle on level ground and move the front wheels to the straight-ahead position.

BO-46974glass removal system is recommended for removing glass without destroying it. Further information can be found in video VT 54.

Before cutting out a stationary window, apply a double layer of masking tape around the perimeter of the painted surfaces.

Removal Procedure
1. Open hood.
2. Disconnect the negative battery cable.
3. Remove the plenum water deflector.
4. Remove the windshield pillar garnish molding.
5. Remove the inside rearview mirror.
6. Remove the front view camera, if equipped.
7. Remove the windshield outside moisture sensor, if equipped.
8. Remove lower windshield trim strip. Remove from guide.







9. NOTE:
- The circumference (2) of the roll of wire is approximately 1 m (3.28 ft).
- The length of wire required for removing the glass is the diagonal length (1) of the windshield multiplied by 4.

Cut the cutting wire to length.
Unroll 6 m (19.68 ft) of cutting wire from the roll of wire.







10. NOTE: Twisting the tip of the awl (1) when inserting it will damage the windshield.

Insert awl through the adhesive bed.







- Insert the awl (2) (by applying pressure and making slight movements parallel with the adhesive bed).
- To make insertion with the awl easier, heat the tip (3) of the awl.

11. NOTE: The cutting wire is bent at right angles to the "tip" of the awl, to minimize resistance when pulling it in.

Attach cutting wire to the awl.







- Thread the cutting wire (1) through the hole of the awl.
- Bend over the cutting wire.

12. NOTE:
- When pulling in the cutting wire do not twist the "tip" (1) of the awl (to avoid damaging the windshield).
- When pulling through, keep the flat side of the awl "tip" (1) parallel with the edge of the windshield.

Pull the awl and cutting wire into the vehicle.
Pull the cutting wire with awl.







13. NOTE: At the windshield, the cutting wire (1) must be rolled under the rubber seal (2) all round. Use soap as an aid.

Lay wire below windshield all round.







14. NOTE:
- Check that the cutting wire is laid correctly at the winch deflection roller. Insert transfer ratchet and pre-tension cutting wire.
- Increased tension is required to cut in the area of the A-pillar/bulkhead.

Position winches in the vehicle.







- Position the winch with one winding head (1) on the right-hand side of the windshield.
- Position the winch with two winding heads (2) in the lower left-hand area of the windshield.
- Attach 2x cutting wire to winch.

15. Cut out windshield.
- Use plastic plate to protect instrument panel padding.
- Cut out the windshield using the winch and two winding heads until the cutting wire is level with the winding head.
- Arrow shows the path taken by the cutting wire.

16. Cut out windshield.
- Use retainers to protect the A-pillar.
- Cut out the windshield using the winch and one winding head until the cutting wire is level with the winding head.
- Arrow shows the path taken by the cutting wire.

17. NOTE:
- Check that the cutting wire is laid correctly at the winch deflection roller.
- Use a lubricant on the deflection roller; more pulling force is required to cut in the windshield radius. Avoid damage to moulded headlining with plastic sheet.

Position winch with one winding head (1) in the vehicle.







- Attach roof frame in the top right-hand area.
- Insert transfer ratchet and pre-tension cutting wire.

18. Cut out windshield.
- Cut out the windshield using the winch and one winding head until the cutting wire is level with the winding head.
- Arrow shows the path taken by the cutting wire.

19. NOTE:
- Check that the cutting wire is laid correctly at the winch deflection roller.
- Avoid damage to moulded headlining with plastic sheet.

Position winch with one winding head (1) in the vehicle.







- Attach roof frame in the left area.
- Insert transfer ratchet and pre-tension cutting wire.

20. Cut out windshield.
- Cut out the windshield using the winch and one winding head until the cutting wire is level with the winding head.
- Arrow shows the path taken by the cutting wire.

21. NOTE:
- Check that the cutting wire is laid correctly at the winch deflection roller.
- Use a lubricant on the deflection roller, more pulling force is required to cut in the windshield corner area.

Position winch with one winding head (1) in the vehicle.







- Attach in the centre area of the windshield.
- Insert transfer ratchet and pre-tension cutting wire.


22. Position winch with two winding heads (2) in the vehicle.
- Attach in the lower left area of the A-pillar.
- Insert transfer ratchet and pre-tension cutting wire.

23. Cut out windshield.
- Cut out the windshield using the winch and two winding heads until the cutting wire is level with the winding head.
- Arrow shows the path taken by the cutting wire.

24. NOTE:
- Check that the cutting wire is laid correctly at the winch deflection roller.
- Use a lubricant on the deflection roller; more pulling force is required to cut in the windshield radius. Avoid damage to moulded headlining with plastic sheet.

Position winch with two winding heads (1) in the vehicle.







- Attach roof frame in the left area.
- Insert transfer ratchet and pre-tension cutting wire.

25. Cut out windshield.
- Cut out the windshield until the cutting wire is level with the winch.
- Arrow shows the path taken by the cutting wire.

26. NOTE:
- Check that the cutting wire is laid correctly at the winch deflection roller.
- Avoid damage to moulded headlining with plastic sheet.
- Second mechanic required.

Position winch with two winding heads (1) in the vehicle.







- Attach roof frame in the right-hand area.
- Insert transfer ratchet and pre-tension cutting wire.

27. Cut out windshield.
- Cut out the windshield until the cutting wire has cut through the adhesive bead completely.
- Arrow shows the path taken by the cutting wire.

28. Remove both cutting tools.
29. Fit BO-641 suction holder.
30. Remove windshield.
31. Cut adhesive bead on the vehicle.
Cut the adhesive bead all round using the knife supplied (1) to around 1 mm (0.04 in) thickness.







32. Repair any paint damage.
Using a touch-up pen to match the color of the vehicle, repair any paint damage.

33. Cut adhesive bead on the rear windshield.
Cut the adhesive bead all round using the knife supplied to around 1 mm (0.04 in) thickness.

Installation Procedure

1. NOTE: Only with new windshield pane.

Apply primer.

2. Apply adhesive bead.
Cut into the tip of the cartridge in such a way that a bead of adhesive approximately 13 mm (0.5 in) thick is produced.







3. Install windshield into the opening.
- Second mechanic required.
- Insert windshield with BO-641 suction holder.
- Position using fibre tape.

4. Remove BO-641 suction holder.
5. Install lower windshield trim strip.
6. Install the plenum water deflector.
7. Install the windshield pillar garnish molding.
8. Install the inside rearview mirror.
9. Install the front view camera, if equipped.
10. Install the windshield outside moisture sensor, if equipped.
11. Connect the negative battery cable.
12. Close the hood.