Windshield: Service and Repair

Windshield Glass

Service Repair No - 76.81.01

Removal

CAUTION:
^ Always protect paintwork and glass when removing exterior components.
^ Always protect the interior components when removing body glass.
^ Lay the glass on felt covered supports. Do not stand on edge as this can cause chips which subsequently develop into cracks.

NOTE: The following equipment is required: / Cutting wire and handles / Kent knife / Glazing knife / Windshield replacement kit / Sealant applicator gun / Suction cups / A felt covered table or stand to support glass.

1. Remove the plenum chamber panel.
2. Remove both A-pillar upper trim panels.
3. Remove the rain sensor.
4. Remove the roof moulding.
^ Release the 6 clips.
^ Repeat the above procedure for the other side.







5. WARNING: Eye protection must be worn.

With assistance, remove the windshield glass.
^ If installed, disconnect the 4 electrical connectors.
^ Carefully cut through the sealant using a glazing knife or cutting wire.
^ Attach the suction cups.
^ Noting fitted position, remove the 4 spacers.







Installation

1. Carefully remove the sealant from the body to leave a smooth surface.
2. Install the windshield glass.
^ Install the spacers equally as shown.
^ Use masking tape to establish reference marks as an alignment aid.







3. Remove the windshield glass.
^ Clean the component mating faces.

4. Apply etch primer to any bare metal.
5. Apply primer over the etch primer.
6. Apply glass primer to the sealant face on the windshield glass and allow to cure.
7. Apply activator over the old sealant on the windshield glass and allow to cure.
8. Fit a pre-cut nozzle to the sealer cartridge, remove the lid, shake out the crystals and fit the cartridge to the applicator gun.
^ Modify the nozzle to achieve a bead section in the shape of a right angle triangle with a base of 8 mm and a vertical height of 12 mm.

9. Apply a continuous bead of sealant to the windshield glass as shown.







10. With assistance, install the window glass.
^ Lightly press the window glass to seat the sealer.
^ Connect the electrical connectors.

11. Test the sealer for leaks, apply additional sealer if necessary. If water is used, allow sealer to dry before testing. Spray water around the glass and check for leaks. Mark any area that leaks. Dry the glass and sealer then apply additional sealer.
12. Install the roof mouldings.
^ Secure with the clips.

13. Install the rain sensor.
14. Install both A-pillar upper trim panels.
15. Install the plenum chamber panel.