Windshield Replacement (Regular Windshield)
Special Tools
• |
BO-46974 Glass
Removal System |
For equivalent regional tools, refer to
Special Tools .
For the needed amount of one part adhesive, refer to
Adhesives, Fluids, Lubricants, and Sealers .
Removal Procedure
Warning: Refer to
Cracked Window Warning .
Warning: Refer to
Glass and Sheet Metal Handling
Warning .
1. |
Position the vehicle on level
ground and move the front wheels to the straight-ahead
position. |
8. |
Use BO-46974
removal system . |
9. |
Take the diagonal measurement
of the windshield. |
10. |
Cut cutting wire into four
times lengths. |
|
Approx. 6200 mm (244.093 in), the circumference of the
corresponding roll of wire is approximately 1000 mm (39.369
in). |
11. |
Heat the awl with a suitable
tool. |
|
Note: Ensure that the
windshield is not damaged in the process, otherwise stress cracks
in the windshield may occur.
|
12. |
Stick the awl (1) with
adhesive bed in the area of the front wall. |
13. |
Pull the wire through.
|
|
• |
Thread the cutting wire into
the hole of the awl and bend it over. |
|
• |
Pull the cutting wire with the
awl to the middle of the steering wheel in the interior.
|
14. |
Release the roof rail front
right and left in direction of arrow. |
|
Note: The cutting
wire (1) should be rolled in beneath the rubber window seal (2) at
the windscreen.
|
15. |
Lay the wire under the
windshield all the way round. |
16. |
Pull the second wire end
through. |
|
• |
Stick awl approx. 1 cm (0.393
in) overlapping the first entry place with adhesive bed.
|
|
• |
Thread the cutting wire into
the hole of the awl and bend it over. |
|
• |
Pull the rest of the wire into
the interior with the awl. |
|
Note: Ensure that the
cutting wire is fitted correctly to the winch deflection
roller.
|
17. |
Place the winch with two
winding heads (2) on windshield inside. |
|
• |
Position winch in right-hand
area of the windshield. |
|
• |
Attach the cutting wire to the
winch. |
|
Note: In the area of
the A-pillar/front wall, increased cutting effort must be made.
|
|
• |
Use the plastic sheet for the
protection of the armature board. |
|
• |
Arrow shows the path taken by
the cutting wire (1). |
|
• |
Insert transfer ratchet and
pre-tension cutting wire. |
|
• |
Cut out the windshield until
the cutting wire is level with the winch. |
|
Note: Ensure that the
cutting wire is fitted correctly to the winch deflection
roller.
|
19. |
Place the winch with two
winding heads (2) in the vehicle. |
|
• |
Position the winch near to the
interior rear view mirror. |
|
• |
Insert transfer ratchet and
pre-tension cutting wire. |
|
Note: In the area of
the A-pillar/roof frame, increased cutting effort must be made.
|
|
• |
Use the hold-down positioner
and the plastic sheet to protect the sunroof. |
|
• |
Arrow shows the path taken by
the cutting wire (1). |
|
• |
Cut out the windshield until
the cutting wire is level with the winch. |
|
Note: Ensure that the
cutting wire is fitted correctly to the winch deflection
roller.
|
21. |
Place the winch with one
winding head in the vehicle. |
|
• |
Position the winch with one
winding head on the A-pillar on the driver's side (2). |
|
• |
Attach the cutting wire (1) to
the winch. |
|
• |
Insert transfer ratchet and
pre-tension cutting wire. |
|
Note: Use lubricant
on the winch deflection roller. More pulling force is required to
cut the area around the A-pillar/bulkhead.
Arrow shows the path taken by the cutting wire.
|
|
• |
Cut out the windshield until
the cutting wire is level with the winch. |
|
• |
Use the plastic sheet for the
protection of the armature board. |
|
Note: Ensure that the
cutting wire is fitted correctly to the winch deflection
roller.
|
23. |
Place the winch with one
winding head in the vehicle. |
|
• |
Position the winch with one
winding head in the area of the roof frame (1). |
|
• |
Insert transfer ratchet and
pre-tension cutting wire (2). |
|
Note: Use lubricant
on the winch deflection roller. More pulling force is required to
cut the area around the A-pillar/roof frame.
Arrow shows the path taken by the cutting wire.
|
|
• |
Cut out the windshield until
the cutting wire is level with the winch. |
|
• |
Use the plastic sheet for the
protection of the ceiling. |
25. |
Position both cutting
tools. |
|
• |
Shift winch with two winding
heads downwards (1). |
|
• |
Shift the winch with one
winding head (2) in the ceiling area so that the cutting wire (3)
is crossed. |
|
• |
Insert transfer ratchet and
pre-tension cutting wire. |
|
Note: Arrow shows the
path taken by the cutting wire.
|
|
• |
Cut out windscreen until the
cutting wire has cut through the adhesive bed completely.
|
|
• |
Use the plastic sheet for the
protection of the ceiling. |
27. |
Remove glass removal
system. |
28. |
Fit and lock BO-641
holder to windshield. |
|
Note: Second mechanic
required.
|
30. |
Cut out the adhesive tape with
the knife provided (1) to within 1 mm (0.039 in). |
31. |
Repair any paint
damage. |
|
Using a touch-up pen to match the color of the vehicle, repair
any paint damage. |
32. |
Cut off the adhesive bead on
the glass pane |
|
Cut out the adhesive tape with the knife provided (1) to within
1 mm (0.039 in). |
Installation Procedure
1. |
Remove all mounds or loose
pieces of urethane adhesive from the pinch-weld area. |
2. |
Inspect for any of the
following problems in order to help prevent future breakage of the
window: |
|
• |
Any other obstruction or
irregularity in the pinch-weld flange. |
3. |
After repairing the opening as
indicated, perform the following steps: |
|
Remove all traces of broken glass from the outer cowl panel,
seats, floor, and defroster ducts. |
|
Cut into the tip of the cartridge in such a way that a bead of
adhesive approx. 13 mm (0.511 in) thick is produced. |
|
• |
Place the windshield on the
roof frames and lower down. |
|
• |
Insert windshield with
BO-641 holder. . |
6. |
Secure windshield in position
with fabric tape. |
7. |
Second mechanic
required. |
8. |
Clean any excess urethane
adhesive from the body. |
9. |
Use a soft spray of warm water
in order to immediately water test the window. |
10. |
Inspect the window for
leaks. |
11. |
If any leaks are found, use a
plastic paddle in order to apply extra urethane adhesive at the
leak point. |
12. |
Retest the window for
leaks. |
13. |
Maintain the following
conditions in order to properly cure the urethane adhesive:
|
|
• |
Partially lower a door window
in order to prevent pressure buildups when closing doors before the
urethane adhesive cures. |
|
• |
Do not drive the vehicle until
the urethane adhesive is cured. Refer to the above curing
times. |
|
• |
Do not use compressed air in
order to dry the urethane adhesive. |
14. |
Install the roof rail front
right and left. |
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