Bonded Heated Front Screen - Removal
NO. 76/01/94/USDATE: 04/01/94/US
MODEL
Range Rover
AFFECTED VEHICLES
Range Rover from VIN LH 647645 with heated front screen
SUBJECT
Bonded Heated Front Screen Removal
DETAIL
Range Rover derivatives from VIN LH 647645 feature a bonded front windscreen. This change was coincident with fascia and electrical revisions, consequently the connections for the heated front screen wiring are now located under the decker panel, which must be removed to gain access.
ACTION REQUIRED
Please alert all workshop personnel and subcontractors to this condition.
PARTS INFORMATION
BTR 9641 Heated front screen
Wind screen finishers:
BTR 9662 Top
BTR 8789 Lower
BTR 9663 Right hand
BTR 9664 Left hand
PROCEDURE
Refer to Workshop Manual section 76 for removal instructions of decker panel/hood and front screen.
Replacement of the front screen involving body panel remove and refit should be carried out in the workshop. If screen remove and refit is sub contracted out, it is recommended that the franchised Dealer completes the panel remove and refit to ensure customer satisfaction.
WINDSCREEN GLASS
Service repair no. 76.81.01
The following equipment is required:
Cutting wire and handles
Windscreen repair kit
Sealant applicator gun
Suction cup lifters
The following materials are required:
Glass cleaning solvent- "Beta Wipe" Glass activator(yellow cap)
Applicator bottle, lint free wipers and cotton buds.
Glass primer - "Beta prime"(green cap)
Body cleaning solvent- Isopropyl alcohol 1000/0
Body primer. "Beta prime 435" paint/plastic primer (red cap)
Applicator bottle and cotton buds.
Betaseal HV3 Adhesive sealant
Self-etch primer 706 A and B
Products supplier - GURIT Essex -
Information
NOTE
A GURIT Essex adhesive and accelerator, may be used, if drive away time is to be kept to a minimum.
Adhesive - Betamate E 2400A
Accelerator - Betamate E 2400B
CAUTION
Once existing sealant is cut, the exposed surfaces oxidizes in approximately 90 minutes. The refit procedure must be completed within this time span to prevent the sealant oxidizing, to reflect a satisfactory joint.
CAUTION
If the windscreen aperture body flange shows signs of corrosion it must be treated with anti corrosion primer and repainted. Newly painted areas must then be left for 12 hours or more before applying adhesive sealant.
NOTE
If heated windscreen: 2 electrical multiplug connectors are located under the decker panel. To access release decker panel.
Remove
1. Remove Windscreen wiper arms.
2. Remove rear view mirror and stickers from glass.
3. Remove "A" post finishers.
4. Fit protective cover over dash panel and apply masking tape to protect "A" posts.
5. Ease one end of bottom finisher away from glass, pull to disengage finisher flange and remove.
6. Lift lip of LH "A" post finisher and release sealing strip along its length, pull to disengage finisher flange from glass and remove.
7. Remove RH "A" post finisher.
8. Remove header finisher.
9. Apply masking tape to protect paint finish around glass.
10. Prepare cutting wire in handle "A". Bend end of wire to handle and tape over end.
11. Force cutting wire through sealer from inside and 100 mm from a top corner. Use a needle if necessary to make a pilot hole.
12. Attach handle "B". Allow 200 mm of wire between handles. Tape over end of wire.
13. With an assistant on the inside: Wedge the tube of the handle "A" between glass and body flange 100 mm ahead of hole in sealer.
14. From the outside: Carefully cut sealer from flange using a straight pull away from the glass. Continue in 100 mm steps around the glass. use a sawing action at the corners.
CAUTION
Along the bottom edge, great care must be taken to cut up to the 2 supports, positions indicated on the obscuration band (See item 18).
15. Remove handle "B". Withdraw the cutting wire and insert it through the sealer between the supports. Refit handle "B".
16. Cut through sealer between the supports. Electric heating: Cut through the 2 wires each side of the supports. Tape cut wires and panels.
17. Attach suction cups to glass and lift glass from body flange, cut sealer free around supports as necessary.
WARNING
If glass has splintered: Protect eyes and operate demister blower at maximum speed to remove any glass from ducts. Use a vacuum cleaner to remove glass particles from inside the vehicle.
Refit
18. Check condition of supports. renew if necessary. Locating studs must be at right angle to flange.
NOTE
The supports were fitted to early vehicles and now replaced with nylon sheaths.
19. Carefully cut back old sealant around body flange to obtain a smooth surface 2 mm thick. DO NOT cut down to flange.
20. Original glass: Cut back old sealant around glass to obtain a smooth surface 2 mm thick. DO NOT cut down to glass surface.
CAUTION
Lay glass on felt covered supports, do not stand on edge. Any chipping of glass edge may develop into cracks.
21. Align header finisher on top edge of glass, push flange fully onto glass and use a wooden block and mallet to ensure fit.
22. Carefully align each side finisher on edge of glass, push flange fully onto glass and use a wooden block and mallet to ensure fit.
23. Apply glass cleaning solvent (yellow cap) to inside face of glass, 20 mm strip around inside of finishers and 30 mm wide along bottom edge.
CAUTION
Do not touch cleaned or primed surfaces with fingers.
24. Apply body cleaning solvent (isopropylene) to body flange and to surfaces covered by the finishers.
25. Shake the primer tins for at least 30 seconds.
26. Apply Glass Primer (green cap) to inside face of glass, 20 mm strip around inside of finishers and 20 mm wide along bottom edge. Use clean gauze to wipe off primed surfaces when dry.
27. Apply Body Primer to body flange.
CAUTION
Use a new sponge and clean bottle for each primer.
28. Remove protective coverings and tape.
29. Fit pre-cut nozzle to sealer cartridge, remove lid and shake out crystals and install in applicator gun.
30. Apply a continuous bead of adhesive sealant around the glass as shown. Vertical edge of sealer to abut finishers and to be 8 mm from bottom edge of glass.
31. Remove protective covering (RED) from side finisher sealing strip.
32. With assistance: Attach suction cups to glass and lift into position, carefully align the indicators on the obscuration band with the supports. Lower screen onto body flange. Check alignment and lightly press to seat sealer.
NOTE
The finisher on later vehicles will not have cutouts, or supports fitted, as shown.
33. Align cut outs with the supports and push finisher fully onto the glass. Use a wooden block to ensure fit.
34. Refit "A" post finishers and interior mirror.
35. Refit wiper arms.
WARRANTY
Normal windscreen warranty policies apply.
COMP. CODE
8G1
SR0
76.10.35 Decker panel (inclusive of hood removal)
01.70 hours
76.81.01 Front screen 02.85 hours