Windshield Glass

WINDSHIELD GLASS

Special Tool(s):

SPECIAL TOOL(S)

REMOVAL

1. WARNING: To prevent glass splinters from entering the eyes or cutting the hands, wear safety glasses and heavy gloves when cutting the glass from the vehicle. Failure to follow these instructions may result in personal injury.

Remove the cowl panel grilles.

2. Remove the A-pillar trim panels.
3. If equipped, remove the overhead console.







4. If equipped, remove the interior lamp.
- Disconnect the electrical connectors.







5. Remove the interior mirror.







6. Remove the screws and the sun visors.







7. Remove the sun visor retaining clips.
1 Open the covers.
2 Remove the screws.







8. Partially lower the headliner and place 2 blocks of suitable material between the headliner and the roof opening to act as spacers.







9. 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.
- Lubricate the urethane adhesive with water to aid the special tool when cutting the urethane adhesive. Using the special tool, place the flat side of the knife against the rear glass.

Start at the top center and work out and down the pillars to the lower corners to the given maximum depths:
1 23 mm
2 75 mm
3 160 mm







10. Install the special tool into the top of the windshield glass and inflate. Cut the urethane adhesive from corner to corner along the bottom of the windshield glass.
11. Remove the windshield glass and the windshield weatherstrip.
12. Using a soft brush or vacuum, remove any dirt or foreign material from the pinch weld.

INSTALLATION

CAUTION: When installing urethane installed glass parts, the vehicle must not be driven until the urethane has cured. At temperatures above 21°C (70°F) and relative humidities above 50%, adequate cure time is typically 24 hours. (Refer to the Essex drive away chart for the cure times as the temperatures and humidity vary). Inadequate or incorrect curing can adversely affect the retention of the windshield.

1. Remove the remaining part of the glass locating pegs from the windshield glass flange.
2. Dry fit the windshield glass to the existing urethane adhesive bead on the body pinch weld. Align the windshield glass in the opening for a uniform fit.
3. Use a non-permanent pencil to make alignment marks on the windshield glass at the setting blocks and the body to aid in the installation alignment of the windshield glass.
4. Remove the windshield glass.







5. NOTE: Avoid scratching the pinch weld.

Trim the remaining urethane adhesive on the pinch weld. The urethane adhesive must be smooth and free of cuts and contamination after trimming. Avoid touching the urethane surface after preparation.

6. Apply urethane metal primer to minor scratches or exposed metal on the pinch weld caused during removal. Do not apply primer to the existing urethane adhesive.
7. If installing the original windshield glass, remove the excess urethane adhesive.
8. Clean the inside of the windshield glass surface with a non-alcohol based glass cleaner.

9. CAUTION: Wipe off the urethane glass prep immediately after each application because it flash dries.

If installing a new windshield glass, apply urethane glass prep to the area to be urethaned.

10. If installing a new windshield glass, apply urethane glass primer to the same area in the previous step. Allow 5 to 7 minutes to dry.







11. Cut the urethane adhesive applicator tip to specification.







12. Apply urethane adhesive on top of the existing trimmed urethane adhesive bead on the pinch weld. Make sure that all gaps in the urethane adhesive are smoothed into one continuous bead.
13. Install the windshield glass weatherstrip.
14. Install the windshield glass on the vehicle aligning it with the markings made previously.
15. Check the windshield glass installation for air or water leaks through the urethane adhesive seal.







16. Remove the spacers and attach the headliner to the roof panel.







17. Install the sun visor retaining clips.
1 Install the screws.
2 Close the covers.







18. Install the sun visors.







19. Install the interior mirror.







20. If equipped, install the interior lamp.
- Connect the electrical connectors.

21. If equipped, install the overhead console.
22. Install the A-pillar trim panels.
23. Install the cowl panel grilles.