Windshield: Service and Repair
Windshield Glass
Special Service Tools
Removal
1. Remove the interior mirror.
2. Remove both A-pillar trim panels.
3. Remove both sun visors.
4. Remove the overhead console.
5. Remove both sun visor retaining clips.
6. NOTE: Right-hand shown, left-hand similar.
Detach the front occupant assist handle screw covers.
7. NOTE: Right-hand shown, left-hand similar.
Remove the front occupant assist handle.
8. Using a suitable adhesive tape, support the headliner.
9. Apply a suitable protective tape to the front edge of the headliner.
10. NOTE: Left-hand shown, right-hand similar.
Disconnect the heated windshield glass electrical connectors.
11. CAUTION: Make sure the windshield finisher insert is not bent on removal. Failure to follow this instruction may result in damage to the component.
Remove the windshield finisher.
12. Remove the cowl vent screen.
13. Apply a suitable protective tape around windshield glass aperture to protect the paintwork.
14. Using a suitable long bladed tool, penetrate the windshield glass adhesive.
15. Place a suitable protective sheet over fascia and place a protecting board over sheet.
16. Dispense 20 ml of WK9L lubricant into the WK9 spray bottle, fill the spray bottle with water and mix.
17. Apply cutting lubricant to the windshield glass adhesive.
18. Prepare the cheese wire and cutting handle.
- Cut a suitable length of cheese wire.
- Install one of the cutting handles to the cheese wire.
19. Pass the free end of the cheese wire through the penetration and install the second cutting handle.
20. WARNING: When removing the windshield glass, personal protection must be worn. Failure to follow this instruction may result in personal injury.
CAUTION:
- Make sure the cheese wire cannot contacted the paintwork while the the windshield adhesive is being cut. Failure to follow this instruction may result in damage to the vehicle.
- Make sure the cheese wire cannot contacted the instrument panel while the the windshield adhesive is being cut. Failure to follow this instruction may result in damage to the vehicle.
- Make sure the cheese wire passes the Vehicle Identification Number (VIN) plate on the correct side. Failure to follow this instruction may result in damage to the component.
NOTE: Apply cutting lubricant to the cheese wire frequently through out the cutting process.
With assistance and exercising care to avoid damaging the paintwork, cut around the windshield glass commencing upwards and along the top.
21. With assistance and exercising care, remove the windshield glass.
1. Attach lifting handles to the windshield glass.
2. Remove the windshield glass.
22. Remove lifting handles from the windshield glass.
Installation
1. WARNING:
- If the windshield glass is being installed at a temperature of 23 degrees C (73 degrees F) or above make sure the vehicle is not driven for at least 1 hour after installation. Failure to follow this instruction, may result in personal injury.
- If the windshield glass is being installed at a temperature of 11 degrees C (52 degrees F) to 23 degrees C (73 degrees F), make sure the vehicle is not driven for at least 1.5 hours after installation. Failure to follow this instruction, may result in personal injury.
- If the windshield glass is being installed at a temperature of 5 degrees C (41 degrees F) to 11 degrees C (52 degrees F), make sure the vehicle is not driven for at least 2 hours after installation. Failure to follow this instruction, may result in personal injury.
- If the windshield glass is being installed at a temperature below 5 degrees C (41 degrees F), use heat and make sure the windshield glass adhesive has set before the vehicle is driven. Failure to follow this instruction, may result in personal injury.
CAUTION: When installing the windshield glass, do not strike it in any way as this will crack the glass. Failure to follow this instruction may result in damage to the component.
NOTE:
- Make sure the windshield glass does not move out of position in the windshield glass aperture.
- If the original windshield glass is to be installed remove the residual adhesive from windshield glass mating surface.
Using the special tool, remove any residual adhesive from the body.
2. Make sure the new windshield glass surface is clean using Betawipe spirit.
3. Apply glass primer to the mating surface of the windshield glass.
4. Install the windshield finisher to the windshield glass.
- Install new windshield finisher retaining clips.
5. Apply glass primer to the mating face of the body flange.
6. Cut adhesive nozzle to achieve a triangular section bead 7 mm (0.28 in) wide by 10 mm (0.39 in) high.
7. Using a suitable pneumatic application gun, apply a uniform bead of adhesive to the windshield glass edge commencing at the bottom center and overlapping the ends approximately 20 mm (0.79 in).
8. CAUTION: When installing the windshield glass, do not strike it in any way as this will crack the windshield glass.
With assistance carefully install the windshield glass into the aperture.
9. Remove the lifting handles.
10. CAUTION: Make sure the windshield glass does not move out of position in the windshield glass aperture.
Apply suitable adhesive tape to the top of the windshield glass.
11. Install the cowl vent screen.
12. Remove the protective tape around windshield glass aperture.
13. Remove protective tape from the leading edge of the headliner.
14. Remove the protective sheet and the protective board from the fascia.
15. NOTE: Left-hand shown, right-hand similar.
Connect the heated windshield electrical connectors.
16. Remove the adhesive tape supporting the headliner.
17. NOTE: Right-hand shown, left-hand similar.
Install the front occupant assist handle.
18. NOTE: Right-hand shown, left-hand similar.
Attach the front occupant assist handle screw covers.
19. Install the sun visor retaining clips.
20. Install the overhead console.
21. Install both sun visors.
22. Install both A-pillar trim panels.
23. Install the interior mirror.