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Liftgate Window Glass > < Glass, Frames and Mechanisms

Fusion 2002.75 (06.2002-)

Glass, Frames and Mechanisms - Windshield Glass Fusion 2002.75 (06/2002-)
Removal and Installation

General Equipment
Hot air gun
Direct glazing cutter for bonded glass
Direct glazing adhesive kit
Direct glazing adhesive oven
Glazing suction cups

Removal

All vehicles
  1. Remove the polyurethane (PU) adhesive cap and heat the PU adhesive for a minimum of 30 minutes.
  1. Raise the hood.

  1. NOTE:
    NOTE:Make sure that the windshield wiper motor is in the park position.
    Remove the windshield wiper arms.

  1. Remove the cowl panel grille side trim panels.

  1. Remove the cowl panel grille.
    1. Remove the screws.
    1. Release the retaining strip.
  1. Lower the hood.

  1. Detach the front door opening weatherstrip from the A-pillar on both sides.

  1. Remove the A-pillar trim panels.
Vehicles with heated windshield
  1. Disconnect the heated windshield electrical connectors (left-hand side shown).
Vehicles with roof opening panel
  1. Remove the overhead console. For additional information, refer to Section  501-12 Instrument Panel and Console.
Vehicles without roof opening panel
  1. Detach the interior lamp.

  1. Disconnect the interior lamp electrical connectors and remove the interior lamp.
All vehicles
  1. Remove the interior mirror.
    • Release the interior mirror retaining clip.

  1. Remove the sun visors.

  1. Lever open the covers to expose the screws and remove the sun visor retaining clips.

  1. 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.

  1. WARNING:
    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:
    CAUTION:Make sure the cutting blades are changed where the cutting depth changes to avoid damage to the body and trim panels.
    NOTE:
    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.
    1. 20 mm.
    1. 35 mm.
    1. 45 mm.
    1. 75 mm.

  1. With the aid of another technician, use glazing suction cups to remove the windshield glass.

  1. Remove the windshield glass locating blocks.
    • Discard the locating blocks.

Installation

All vehicles
  1. CAUTION:
    CAUTION:Do not touch the adhesive surface as re-bonding will be impaired.
    Carefully trim the remaining polyurethane (PU) adhesive from the windshield glass flange to leave approximately 1 mm of trimmed PU adhesive adhered to the flange.

  1. Install new windshield glass locating blocks.
  1. Check the windshield glass flange for damaged sheet metal, rust or foreign material which may have caused, or may cause, glass breakage.
  1. CAUTION:
    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.
  1. Prepare the glass, windshield glass flange and trimmed PU adhesive in accordance with the instructions supplied with the PU adhesive kit.

  1. NOTE:
    NOTE:Discard the first 100 mm of PU adhesive as this may have a reduced working time.
    NOTE:
    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.

  1. With the aid of another technician, use glazing suction cups to install the windshield glass.
    • Press firmly and evenly into position.
  1. CAUTION:
    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 opened and closed.
    Using suitable tape, secure the windshield glass in the correct position until the PU adhesive has cured.

  1. 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).

  1. Remove the spacers and attach the leading edge of the headliner to the roof panel.

  1. Install the sun visor retaining clips.

  1. Install the sun visors.

  1. Install the interior mirror.
Vehicles without roof opening panel
  1. Connect the interior lamp electrical connectors.

  1. Install the interior lamp.
Vehicles with roof opening panel
  1. Install the overhead console. For additional information, refer to Section  501-12 Instrument Panel and Console.
Vehicles with heated windshield
  1. Connect the heated windshield electrical connectors (left-hand side shown).
All vehicles
  1. Install the A-pillar trim panels.

  1. Attach the front door opening weatherstrip to the A-pillar on both sides.
  1. Raise the hood.

  1. Install the cowl panel grille.
    1. Locate the retaining strip.
    1. Install the screws.

  1. Install the cowl panel grille side trim panels.

  1. Install the windshield wiper arms.
  1. Lower the hood.

Liftgate Window Glass > < Glass, Frames and Mechanisms