Windshield: Service and Repair
FRONT WINDSHIELD REPLACEMENT
REMOVE WINDSHIELD
CAUTION: USE MASKING TAPE TO AVOID DAMAGE TO PAINT WORK.
- Open hood.
- Remove windshield wipers.
- Loosen and pull forward cover panel over wiper well.
- Use blade to remove mouldings along A-posts.
- Place blade against windshield. Do not pry against glass.
- Remove cover strip on roof.
- At bottom of windshield; remove horizontal cover strip and cover panel guide moulding.
- Thread piano wire from inside to outside through PUR bead.
- Use needle-nosed pliers to pull wire from outside.
- Attach wire to handle on outside and to counterhold inside car.
TWO-MAN OPERATION:
CAUTION: USE CARE TO AVOID DAMAGE TO INTERIOR FITTINGS AND PAINTWORK.
- Hold counterhold as far away as possible in firm contact with PUR bead at inside of windshield. Exert smooth, gentle pulling action on handle outside. Pause and move counterhold gradually while maintaining tension on wire.
- "Saw" around corners. Take particular care at roof edge moulding.
- Attach suction cups to windshield and lift out glass.
TREATMENT OF PUR ON BODY FLANGE
WARNING: USE OF PROTECTIVE GLOVES IS RECOMMENDED. ENSURE THAT VENTILATION IS SATISFACTORY.
If surface is uneven, use chisel approx. 13 mm wide to even bead.
After removing windshield, wash adhesive remaining on body with cleaning agent.
CAUTION: DO NOT USE GLASS ACTIVATOR FOR THIS PURPOSE.
WARNING: DO NOT TOUCH BEAD WITH HANDS.
BODYWORK
If any part of windshield opening requires painting, body flange must be masked after application of sealing coat. Masking should be removed when all painting has been completed.
If body flange has been painted with top coat, primer must be applied to ensure maximum adhesion of PUR.
PREPARATIONS FOR INSTALLING WINDSHIELD
- Cut away all PUR from upper body flange.
- Use cleaning agent H to clean dirt from upper body flange and edge between flange and roof
INSTALL SUPPORT:
- Peel backing paper from tapes on support.
- Attach support to body flange and to edge between flange and roof (1).
- Apply PUR bead to body flange below support. Bead should be 6-7 mm high and should extend from A- post to A-post (2).
INSTALL LOWER SPACERS:
Measure off 260 mm from inner edge of each front fender along bottom of windshield frame.
- Use cleaning agent H to clean area starting 260 mm from edge of each front fender (equal to length of spacers).
- Apply double-sided adhesive tape to rear of spacers.
- Attach spacers to windshield frame.
- Remove backing tape from front of spacers.
INSTALLATION OF WINDSHIELD
- Place windshield on stand.
- Measure off 740 mm from top of windshield (where PUR bead is to be applied to glass).
- Mark with masking tape.
- Install guide moulding for wiper well cover panel.
- Attach suction cups to windshield.
WARNING: USE OF PROTECTIVE GLOVES IS RECOMMENDED. ENSURE THAT VENTILATION IS SATISFACTORY.
- Use cleaning agent H to clean all surfaces where adhesive is to be applied.
- Apply glass activator to surface where adhesive is to be applied.
- Apply glass primer to surface where adhesive is to be applied.
- Apply liberally without allowing primer to ran.
- Allow primer to dry until surface is matt.
- Cut off bottom of adhesive cartridge. Pour out drying agent (small pellets in bottom of cartridge).
- Cut hole in front end.
Check if bonding kit contains blue nozzle. If so, use this nozzle. If blue nozzle is not provided: Take complete, intact nozzle:
- Measure off and cut 55 mm from base: cut off nozzle.
- Drill 3 mm (1/8") diameter hole 36.5 mm from base.
- Measure off 8 mm at tip.
- Cut nozzle to shape.
Nozzle made as described provides PUR bead measurement at 28 mm in height and 8 mm at base.
NOTE: THIS HEIGHT OF BEAD IS REQUIRED ONLY ON CLEAN METAL.
- Attach nozzle to cartridge and fit cartridge in adhesive gun.
- Apply adhesive to windshield.
- Hold gun at right-angles to glass.
- Move gun slowly around windshield. Ensure that bead is continuous and unbroken, otherwise joint will leak.
- Place windshield in position. Ensure that upper section is resting on upper supports and that windshield is positioned as high as possible against trim moulding retainer.
- Press bottom edge of windshield with hand so that glass adheres to tape on lower spacers.
- Attach several strips of masking tape to windshield and roof to prevent windshield slipping downward while adhesive is setting.
ADHESIVE MUST HAVE HARDENED SUFFICIENTLY TO ENSURE THAT WINDSHIELD DOES NOT MOVE WHEN INSTALLING WIPER WELL COVER PANEL.
Drying time is at least 4 hours. High humidity enhances the drying time. Placing wet cloths around edges will improve drying results.
INSTALL:
- cover panel
- windshield wipers
- upper trim moulding in retainer
- A-post and roof mouldings
TEST SEAL WITH WATER.