Windshield: Service and Repair

76.81.01 Windscreen

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

Remove

1. Remove roof finishers.

WARNING: Wear protective gloves when handling glass, solvents and primers.

2. Remove windscreen side finishers.

WARNING: Wear suitable eye protection when removing and refitting glass.

3. Remove windscreen lower finisher.
4. Remove interior mirror.
5. Remove rain sensor, if fitted.
6. Remove 'A' post upper finishers.







7. Disconnect screen heater multiplugs.
8. Protect exterior body work adjacent to windscreen.
9. Cover heater ducts with masking tape.
10. Protect fascia and interior of vehicle.







11. Release and remove upper finisher from windscreen.







12. From outside of vehicle, use a Kent knife and carefully cut through sealant securing upper and both sides of windscreen to body.
13. If necessary, use cutting wire to cut through any remaining sealant securing top and sides of windscreen.







14. From inside vehicle, carefully cut through sealant securing lower edge of windscreen with a glazing knife. It is not practical to use a Kent knife as the windscreen is very close to body.
15. Attach suction cups and with assistance, remove windscreen and place on stand.

CAUTION: Lay glass on felt covered supports and be careful not to damage the obscuration band. Do not stand on edge as this can cause chips which subsequently develop into cracks.







16. Remove 4 windscreen support blocks from body.

Refit

1. Carefully remove sealant from body to leave a smooth surface.
2. Original windscreen: Carefully cut back sealant to obtain a smooth surface without damage to obscuration band.
3. Fit upper finisher to windscreen.
4. Fit support blocks to body.
5. Fit windscreen to body and centralize in aperture.







6. Use masking tape to establish reference marks as an alignment aid.
7. Remove windscreen and place on stand.
8. Clean sealant face on body and windscreen with solvent.
9. Apply etch primer to any bare metal on body.
10. Apply primer over etch primer.
11. Apply screen primer to sealant face on windscreen and allow to cure.
12. Apply activator over old sealant on body and allow to cure.
13. Fit pre-cut nozzle to sealer cartridge, remove lid, shake out crystals and fit cartridge to applicator gun. If necessary modify the nozzle to achieve required bead section.







14. Apply a continuous bead of sealant to windscreen as shown.
15. With assistance, fit and align windscreen. Lightly press windscreen to seat sealer.
16. Remove protective covers and tape.
17. Test sealer for leaks, apply additional sealer if necessary. If water is used, allow sealer to dry before testing. Spray water around glass and check for leaks. Mark any area that leaks. Dry glass and sealer then apply additional sealer.
18. Connect screen heater multiplugs and align harness.
19. Fit 'A' post upper finishers.
20. Fit rain sensor, if fitted.
21. Fit interior mirror.
22. Fit windscreen lower finisher.
23. Fit windscreen side finishers.
24. Fit roof finishers.