Windshield: Service and Repair
Interior Auto Glass Cut-Out Knife Kit:
Special Tool(s)
REMOVAL
1. Remove the windshield wiper pivot arms.
2. Remove the cowl top vent panel.
3. Drill out the rivets and remove the windshield glass stops.
4. Remove the inside rear view mirror.
5. Remove (pull off) the RH and LH A-pillar mouldings.
6. Lower the front portion of the roof trim panel.
7. Lubricate the urethane sealant with ECL-784 lubricant (10:1 ratio of water to soap) to aid the Rotunda Interior Glass Cut-Out Knife Kit when cutting the urethane sealant.
8. Insert Rotunda Interior Glass Cut-Out Knife into the urethane sealant at the upper center of the vehicle interior and work toward the bottom corners.
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.
CAUTION: To prevent damage to the windshield header seal, turn the blade so that the flat side is against the pinch weld.
9. Insert Rotunda interior Glass Cut-Out Knife into the bottom center of the urethane sealant on the vehicle exterior and work toward the corners.
NOTE: Support the windshield glass to prevent the glass from dropping before cutting the bottom edge of the urethane sealant.
10. Carefully remove the windshield glass from the vehicle.
CAUTION: Removing the glass requires more than one technician.
11. Remove the windshield header seal.
12. Trim the remaining urethane on the pinch weld to within the specification.
^ The old urethane should be smooth and free of cuts and contamination.
INSTALLATION
1. Check the pinch weld for damaged sheet metal, raised sheet metal at the spot welds, rust or foreign material that could cause glass damage.
2. Apply Urethane Body Primer WSB-M2G234-C to any exposed metal on the pinch weld.
3. If re-installing the same windshield glass, removal all remaining traces of urethane sealant.
4. Clean the inside of the windshield glass with an alcohol free cleaner.
5. Apply Glass Primer WSB-M5B280-C2 (red) to the entire inside perimeter of the windshield glass. Wipe off immediately.
NOTE: Apply with deliberate strokes, making sure not to overlap the applied area.
6. Apply Glass Primer WSB-M2G314-B (black) to the entire inside perimeter of the windshield glass. Allow a minimum of 5 minutes dry time.
7. Install the windshield header seal on the windshield glass.
8. Apply an 11 mm (0.43 inch) bead of Urethane Sealant to the entire primed area of the windshield glass.
NOTE: The windshield glass must be positioned within 10 minutes of applying the urethane sealant.
9. Position the windshield glass on the vehicle pinch weld and center the glass in the opening.
CAUTION: After replacing the urethane installed glass, the vehicle should not be driven until the urethane has cured. The curing times at temperatures above 13°C (55°F) and relative humidity above 50% is 12 to 24 hours (decreasing at higher temperatures and lower humidities). Inadequate curing of the urethane can adversely affect the strength of the urethane sealant bond.
10. Position the windshield glass stops on the vehicle. Adjust glass height and rivet the stops in position.
11. Wipe off any excess urethane sealant and apply a 6 mm (0.23 inch) bead of Pumpable Foam Dam ESB-M4G309-A between the windshield header seal and the urethane sealant.
12. Fill cavity between both the LH and RH side of the windshield header seal and the sheet metal using RTV Sealer ESB-M4G92 for a total length of 50 mm (2 inches) from the base of the A-pillars.
13. Install the inside rear view mirror.
14. Install the roof trim panel.
15. Install (push on) the LH and RH A-pillar mouldings.
16. Install the cowl top vent panel.
17. Install the windshield wiper pivot arms.