| Removal and Installation Hot air gun Direct glazing cutter for bonded glass Direct glazing adhesive kit Direct glazing adhesive oven Glazing suction cups Removal All vehicles | | -
Remove the polyurethane (PU) adhesive cap and heat the PU adhesive for a minimum of 30 minutes. | | | -
NOTE:Make sure that the windshield wiper motor is in the park position. Remove the windshield wiper arms. | | | -
Remove the cowl panels. - Pull the cowl panels out of the retaining groove.
| Vehicles with heated windshield | | -
Disconnect the heated windshield electrical connectors (left-hand side shown). | All vehicles | | -
Remove the A-pillar exterior trim panels. | Vehicles with manual dimming interior mirror | | -
Remove the manual dimming interior mirror. | Vehicles with auto-dimming interior mirror | | -
Remove the auto-dimming interior mirror.
For additional information, refer to: Auto-Dimming Interior Mirror (501-09 Rear View Mirrors, Removal and Installation).
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Remove the rain sensor (if equipped). - Disconnect the electrical connector.
- Release the clips.
- Remove the rain sensor.
| All vehicles | | -
Lever open the covers to expose the screws and remove the sun visor retaining clips. | | | -
Remove the overhead console.
For additional information, refer to: Overhead Console (501-12 Instrument Panel and Console, Removal and Installation).
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Remove the A-pillar trim panels.
For additional information, refer to: A-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
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Detach the leading edge of the headliner and place two blocks of suitable material between the headliner and the roof panel to act as spacers. | | | -
WARNING:Wear gloves and eye protection when working with the glass cutting tool as the cutting operation may produce splinters. When using the cutter wear ear protectors. Failure to follow these instructions may result in personal injury. CAUTION:Make sure the cutting blades are changed where the cutting depth changes to avoid damage to the body and trim panels. NOTE:Some resistance may be encountered when cutting through the glass locating pegs in the lower corners of the glass. NOTE:Care must be taken when cutting in the area of the locating blocks along the lower edge of the windshield glass. From inside the vehicle, using a suitable direct glazing cutter, cut the PU adhesive to the given maximum depths. - 15 mm.
- 20 mm.
- 25 mm.
- 40 mm.
- 70 mm.
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With the aid of another technician, use glazing suction cups to remove the windshield glass. | Installation All vehicles | | -
Carefully remove the remaining part of the glass locating pegs from the windshield glass flange. | | | -
CAUTION:Do not touch the adhesive surface as re-bonding will be impaired. Carefully trim the remaining PU adhesive from the windshield glass flange to leave approximately 1 mm of trimmed PU adhesive adhered to the flange. | | | -
Check the windshield glass flange for damaged sheet metal, rust or foreign material which may have caused, or may cause, glass breakage. | | | -
CAUTION:To make sure that the PU adhesive cures, it is essential that all bonding surfaces are free of moisture. Using a hot air gun, apply warm air (25°C) to the windshield glass flange and glass bond line to remove all traces of moisture. | | | -
Prepare the glass, windshield glass flange and trimmed PU adhesive in accordance with the instructions supplied with the PU adhesive kit.
For additional information, refer to: Specifications (501-11 Glass, Frames and Mechanisms, Specifications).
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NOTE:Discard the first 100 mm of PU adhesive as this may have a reduced working time. NOTE:To avoid water leaks, any breakage in the continuous bead must be overlapped by 20 mm. Apply the PU adhesive in a continuous bead of between 8 and 10 mm in height to the windshield glass flange along the bond line. | | | -
With the aid of another technician, use glazing suction cups to install the windshield glass. - Press firmly and evenly into position.
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CAUTION:During the curing period of the PU adhesive, the door windows must be left open to avoid a build up of pressure when the doors are open and closed. Using suitable tape, secure the windshield glass in the correct position until the PU adhesive has cured. | | | -
If the ambient temperature falls below 10°C, use a hot air gun and apply warm air (25°C) continuously for 15 minutes (inside or outside the vehicle). | | | -
Remove the spacers and attach the leading edge of the headliner to the roof panel. | | | -
Install the A-pillar trim panels.
For additional information, refer to: A-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
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Install the overhead console.
For additional information, refer to: Overhead Console (501-12 Instrument Panel and Console, Removal and Installation).
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Install the sun visor retaining clips. | Vehicles with manual dimming interior mirror | | -
Install the manual dimming interior mirror. | Vehicles with auto-dimming interior mirror | | -
Install the rain sensor (if equipped). - Locate the rain sensor in the rain sensor mounting bracket.
- Push in the clips.
- Connect the electrical connector.
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Install the auto-dimming interior mirror.
For additional information, refer to: Auto-Dimming Interior Mirror (501-09 Rear View Mirrors, Removal and Installation).
| All vehicles | | -
Install the A-pillar exterior trim panels. | Vehicles with heated windshield | | -
Connect the heated windshield electrical connectors (left-hand side shown). | All vehicles | | -
Install the windshield wiper arms. | |
