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Rear Door Glass Top Run > < Front Door Glass Top Run

Ikon 1999 (01.2000-)

Glass, Frames and Mechanisms - Windshield Glass Ikon 1999 (01/2000-)
Removal and Installation

General Equipment
Hot air gun
Direct glazing cutter for bonded glass
Mixer/Application gun

Removal

  1. Disconnect the battery ground cable. For additional information, refer to Section  414-01 Battery, Mounting and Cables.

  1. NOTE:
    NOTE:Should the ambient temperature fall below 10°C heat the cartridges for approximately 15 minutes by placing them on a warm radiator, or by using a hot air gun set at approximately 25°C.
    Heat the polyurethane (PU) adhesive if necessary.
  1. Raise the hood.

  1. Remove the windshield wipers.
  1. Lower the hood.
  1. Remove the interior lamp. For additional information, refer to Section  417-02 Interior Lighting.

  1. Remove the sun visors.

  1. Remove the sun visor retaining clip.
    1. Open the screw cover.
    1. Remove the screw.
  1. Remove the rear view mirror.

  1. Detach the door weatherstrip on each side.

  1. Remove the A-pillar trim panels on each side.
    1. Unclip the trim panel.
    1. Slide the trim panel upwards.

  1. Detach the front of the headliner.
    • 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:Some resistance may be encountered when cutting through the glass locating pegs in the top corners of the glass.
    NOTE:
    NOTE:Carefully remove the remaining part of the locating pegs from the window opening flange.
    From inside the vehicle cut the PU adhesive at the given maximum depths. Use the recommended blades, following the proprietary tool manufacturers instructions.
    1. 15 mm.
    1. 18 mm.

  1. With the aid of another technician, use suction cups to remove the windshield.
  1. Remove the windshield weatherstrip.

Installation
  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.
    CAUTION:
    CAUTION:Avoid touching the trimmed surface as this will inhibit the bonding of the new adhesive.
    Remove the excess PU adhesive from the opening flange.
    • Carefully trim the remaining PU adhesive from the windshield opening flange to leave approximately 1 mm of trimmed PU adhesive adhered to the opening flange.
  1. Check the pinch weld sealing area for damaged sheet metal, rust or foreign material which may have caused, or may cause glass breakage.

  1. CAUTION:
    CAUTION:To make sure 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 opening flange and glass bond line to remove all traces of moisture.
  1. Prepare the glass, windshield opening and trimmed PU adhesive in accordance with the instructions supplied with the 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 should be overlapped by 20 mm.
    Apply a thin continuous bead of PU adhesive to the edge of the windshield.
  1. Install the windshield weatherstrip.

  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 should be overlapped by 20 mm.
    Apply the PU adhesive in a continuous bead of between 8 and 10 mm height to the windshield opening flange along the bond line.

  1. NOTE:
    NOTE:Firmly and evenly press in position.
    With the aid of another technician, use suction cups to install the windshield.

  1. Should the ambient temperature fall below 10°C use a hot air gun at a distance of approximately 50 mm from the surface and apply warm air (25°C) continuously for 15 minutes (inside or outside the vehicle).

  1. Install the headliner.
    • Remove the spacers.
  1. Install the A-pillar trim panels on each side.

  1. Attach the door weatherstrip on each side.
  1. Install the rear view mirror.

  1. Install the sun visor retaining clips.
    1. Install the screw.
    1. Close the screw cover.

  1. Install the sun visors.
  1. Install the interior lamp. For additional information, refer to Section  417-02 Interior Lighting.
  1. Raise the hood.

  1. Install the windshield wipers.
  1. Lower the hood.
  1. Connect the battery ground cable. For additional information, refer to Section  414-01 Battery, Mounting and Cables.

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