Windscreen

76.81.01 Windscreen

Introduction

The following equipment is required:
- Cutting wire and handles.
- Kent cutting knife.
- Glazing knife.
- Windscreen repair kit.
- Sealant applicator gun.
- Suction cups.
- A felt covered table or stand to support glass.

WARNING:
- Wear protective gloves when handling glass, solvents and primers.
- Wear suitable eye protection when removing and refitting glass.
- If glass has splintered, protect eyes and operate demister blower to remove glass from heater ducts. Use a vacuum cleaner to remove glass from fascia, carpet and seats.

Remove

1. Remove air intake plenum.







2. If fitted, disconnect screen heater multiplugs.
3. Remove top corner trim finishers from body.
4. Remove windscreen top finisher and discard.







5. Release interior mirror from slug and tie aside.
6. Fit protection to exterior body work adjacent to screen.
7. Cover body panels adjacent to glass.
8. Cover heater ducts with masking tape.
9. Cover interior of vehicle with protective sheet.







10. From outside of vehicle, use a Kent knife and carefully cut through sealant securing sides of screen to body.
11. Using suitable cutting wire, with assistance if required, carefully cut through sealant securing top of screen to body and any remaining sealant at sides.

CAUTION: Hold the cutting wire as close to the glass as possible to prevent damage to the body and surrounding trim.

12. Cut through sealant securing lower edge of screen to body with glazing knife.
13. Attach suction cups and use assistance to remove glass from body.

CAUTION: Lay glass on felt covered supports and be careful not to damage the obscuration band. Do not stand on edge as this can cause chips which subsequently develop into cracks.

14. Collect screen support block.

Refit
1. Carefully remove sealant from body to leave a smooth surface.
2. Use a vacuum cleaner to clear away any waste.
3. Original glass:Carefully cut back old sealer to obtain a smooth surface without damaging obscuration band on glass. Fit new top finisher to screen.







4. Fit screen support block to body.
5. With assistance, locate screen to body.
6. Apply masking tape to establish reference marks as an alignment aid.
7. With assistance, remove screen and place aside.
8. Clean body and sealant face on screen with solvent.

CAUTION: Do not touch cleaned or primed surfaces with fingers.

9. Apply etch primer to any bare metal on frame.
10. Apply screen primer to sealant face on screen and allow to cure.
11. Apply primer over etch primer on body.
12. Apply activator over old sealant on body.
13. Allow activator to cure.
14. Fit pre-cut nozzle to sealer cartridge, remove lid, shake out crystals and fit cartridge to applicator gun. If necessary modify the nozzle to achieve required bead section.







15. Apply a continuous bead of sealant to sealant face on screen as shown.
16. With assistance, lift screen into place and align to screen supports and tape. Ensure top finisher is located into correct position. Lightly press glass to fully seat sealer.

CAUTION: Do not apply heavy pressure to the sides of the windscreen. Lightly press windscreen from centre outwards until edges are to required gap. Pushing sides into position can bend windscreen and lead to cracking in service.

17. Remove protective covers and tape.
18. Test sealer for leaks, apply additional sealer if necessary. If water is used, allow sealer to dry before testing. Spray water around glass and check for leaks. Mark any area that leaks. Dry glass and sealer then apply additional sealer.
19. Fit interior mirror to slug.
20. If applicable, connect screen heater multiplugs.
21. Fit air intake plenum.

CAUTION:
- A curing time of 6 hours is desirable. During this time leave a window open to ventilate the vehicle interior. If the vehicle must be used before the curing time has elapsed, do not drive at speed or slam the doors with the windows closed.
- Vehicles fitted with a passenger airbag should not be driven for 24 hours.