| Removal and Installation | Fein Cutter Blade No. 63903076016 | | Fein Cutter Blade No. 63903113022 | | Fein Oscillating Cutter | FDEP 2583391 | Remove | | 1. Disconnect the battery earth lead. | | |  | NOTE: If your repair kit is the new 2K‐PU adhesive, substitute the new instructions supplied in the kit where necessary. | 2. Check the contents of the repair kit. • Adhesive • Cleaner • Primer • Cloth • Wire wool • Felt pad • Applicator nozzle | | | | | NOTE: It is possible that a second tube of adhesive may be required for this operation. | 3. Heat the adhesive. Place the cartridge of P.U. adhesive in warm water for a period of five to ten minutes. 4. Remove the cowl top grille panel and wipers (refer to Operation No. 43 230 0). | | | 5. Remove the windscreen weatherstrip trim. | | NOTE: The weatherstrip trim will be damaged during removal and must therefore be renewed. | 6. Apply several layers of protective masking tape to the bodywork around the screen. | | | 7. Remove the two A ‐ pillar trims (refer to Operation No. 43 616 0), and disconnect the heated windscreen wires (where fitted). 8. Remove the interior mirror. Using the Fein cutter with trimming blade, or a small length of wire from the repair kit, slice through the adhesive patch. | | | 9. Remove the interior windscreen spacer from the aperture flange. Pull the rubber trim spacer from the flange. | | | 10. Fit Fein cutter blade 63903076016 (24mm Hooked Blade) to the cutter. | | | |  | WARNING: Always wear gloves and eye protection when working with the glass cutting tool as splinters may occur from the edge of the window during cutting. | 11. Cut the glass adhesive – sides and top. From the outside and starting in the bottom left‐hand corner, cut the P.U. adhesive up the left‐hand side, along the top and down the right‐hand side. | | | | | WARNING: Splinters may occur during this process and you must always wear gloves and eye protection when working with glass. | | | NOTE: The screen is positioned by Two height adjuster blocks fixed on the bottom edge of the glass. These should be levered off before cutting. | 12. Cut the bottom glass adhesive. | | | 13. Cut the bottom glass adhesive (cont'd). From the outside, cut from the centre outwards. 14. Carefully remove the glass. | | | 15. Remove the windscreen rubber edge trim. | Install | | | | NOTE: Avoid touching the trimmed surface as this will prevent the new adhesive from properly bonding. | 16. Trim the aperture. • Fit Fein cutter blade No. 63903113022. • Carefully trim the remaining P.U. adhesive from the window aperture to leave approximately one mm of trimmed P.U. fixed to the bodywork. | | 17. Clean the glass. Carefully trim the old adhesive from the window to leave approximately one mm of trimmed P.U. fixed to the glass. | | |  | CAUTION: The glass primer contains solvents that evaporate to enable the primer to harden. These solvents will soften synthetic paint finishes. Therefore it is important to use `ZK' acrylic finishing paints mixed with a hardener in the window surround areas. | 18. Prepare the surface. If the fitment area is repainted prior to installing the glass, this must be coated with primer from the repair kit and allowed to dry. | | | 19. Fit a new windscreen rubber edge trim. • Align the moulding to the windscreen centring notch and push on. • Cut the bottom ends to length as necessary. | | | 20. Fit new height adjuster blocks to the bottom edge of the windscreen. • Clip into position as marked by the centring notches in the glass. • Turn both the screw adjusters to provide maximum glass lift. • Offer the glass to the aperture and check the gap between the top of the windscreen and the body aperture is between two and four millimetres. Adjust as necessary. | | | 21. Refit the interior windscreen spacer to the aperture flange. Ensure the joint is positioned in the centre of the bottom flange. | | | 22. Fit the windscreen weatherstrip trim. | | | | NOTE: To avoid water leaks, any breakage in the continuous bead should be overlapped by 20 mm (0,79 in). | 23. Apply adhesive. The adhesive bead should be an even and continuous triangular profile of approximately 14 mm (0,55 in) in height. | | | 24. Fit the glass. • Lift the glass into position and centralise. • Check the glass to aperture height adjustment to ensure correct positioning and readjust if necessary. • Press the glass firmly into the adhesive, starting with pressure at the centre and working outwards. | | | | WARNING: For vehicles fitted with a passenger side airbag this curing period must be extended to a minimum of ten hours. The passenger side airbag utilises the windscreen as a pressure base during deployment and it is therefore essential to ensure the curing process has been fully completed. | | | NOTE: The vehicle must be left with the windows open in a warm atmosphere, above 0°C, for a minimum of two hours to enable the P.U. adhesive to cure properly (refer to the information provided in Description and Operation). | 25. Refit the remaining components in reverse order. | |
