Windshield Replacement
Windshield Replacement |
Special Tools
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BO-641
Suction Holder
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BO-46974
Glass Removal System
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For equivalent regional tools, refer to Special Tools .
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Note | ||
The following document describes the procedure for removing the windshield using BO-46974 glass removal system. As a supplement to the existing video VT 54, concise steps will be shown for removing the windshield without destroying it. With the introduction of BO-46974 glass removal system , the conventional glass removing methods are no longer used. |
Position the vehicle on level ground and move the front wheels to the straight-ahead position.
BO-46974 glass removal system is recommended for removing glass without destroying it. Further information can be found in video VT 54.
Before cutting out a stationary window, apply a double layer of masking tape around the perimeter of the painted surfaces.
Removal Procedure |
1. |
Open hood.
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2. |
Disconnect the negative battery cable. Refer to
Battery Negative Cable Disconnection and Connection
.
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3. |
Remove the plenum water deflector. Refer to
Plenum Water Deflector Replacement
.
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4. |
Remove the windshield pillar garnish molding. Refer to
Windshield Side Garnish Molding Replacement
.
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5. |
Remove the inside rearview mirror. Refer to
Inside Rearview Mirror Replacement
.
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6. |
Remove the front view camera, if equipped. Refer to
Front View Camera Replacement (Object Lens Cleaning)
Front View Camera Replacement (Base)
.
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7. |
Remove the windshield outside moisture sensor, if equipped. Refer to
Windshield Outside Moisture and Headlamp Automatic Control Ambient Light Sensor Replacement
.
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8. |
Remove lower windshield trim strip.
Remove from guide. |
10. |
Insert awl through the adhesive bed. |
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Insert the awl (2) (by applying pressure and making slight movements parallel with the adhesive bed).
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To make insertion with the awl easier, heat the tip (3) of the awl.
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11. |
Attach cutting wire to the awl. |
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Thread the cutting wire (1) through the hole of the awl.
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Bend over the cutting wire.
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12. |
Pull the awl and cutting wire into the vehicle. Pull the cutting wire with awl. |
13. |
Lay wire below windshield all round. |
14. |
Position winches in the vehicle. |
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Position the winch with one winding head (1) on the right-hand side of the windshield.
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Position the winch with two winding heads (2) in the lower left-hand area of the windshield.
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Attach 2x cutting wire to winch.
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15. |
Cut out windshield.
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Use plastic plate to protect instrument panel padding.
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Cut out the windshield using the winch and two winding heads until the cutting wire is level with the winding head.
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Arrow shows the path taken by the cutting wire.
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16. |
Cut out windshield.
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Use retainers to protect the A-pillar.
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Cut out the windshield using the winch and one winding head until the cutting wire is level with the winding head.
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Arrow shows the path taken by the cutting wire.
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17. |
Position winch with one winding head (1) in the vehicle. |
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Attach roof frame in the top right-hand area.
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Insert transfer ratchet and pre-tension cutting wire.
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18. |
Cut out windshield.
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Cut out the windshield using the winch and one winding head until the cutting wire is level with the winding head.
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Arrow shows the path taken by the cutting wire.
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19. |
Position winch with one winding head (1) in the vehicle. |
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Attach roof frame in the left area.
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Insert transfer ratchet and pre-tension cutting wire.
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20. |
Cut out windshield.
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Cut out the windshield using the winch and one winding head until the cutting wire is level with the winding head.
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Arrow shows the path taken by the cutting wire.
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21. |
Position winch with one winding head (1) in the vehicle. |
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Attach in the centre area of the windshield.
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Insert transfer ratchet and pre-tension cutting wire.
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22. |
Position winch with two winding heads (2) in the vehicle.
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Attach in the lower left area of the A-pillar.
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Insert transfer ratchet and pre-tension cutting wire.
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23. |
Cut out windshield.
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Cut out the windshield using the winch and two winding heads until the cutting wire is level with the winding head.
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Arrow shows the path taken by the cutting wire.
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24. |
Position winch with two winding heads (1) in the vehicle. |
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Attach roof frame in the left area.
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Insert transfer ratchet and pre-tension cutting wire.
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25. |
Cut out windshield.
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Cut out the windshield until the cutting wire is level with the winch.
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Arrow shows the path taken by the cutting wire.
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26. |
Position winch with two winding heads (1) in the vehicle. |
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Attach roof frame in the right-hand area.
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Insert transfer ratchet and pre-tension cutting wire.
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27. |
Cut out windshield.
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Cut out the windshield until the cutting wire has cut through the adhesive bead completely.
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Arrow shows the path taken by the cutting wire.
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28. |
Remove both cutting tools.
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29. |
Fit
BO-641
suction holder.
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30. |
Remove windshield.
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31. |
Cut adhesive bead on the vehicle.
Cut the adhesive bead all round using the knife supplied (1) to around 1 mm (0.04 in) thickness. |
32. |
Repair any paint damage.
Using a touch-up pen to match the color of the vehicle, repair any paint damage. |
33. |
Cut adhesive bead on the rear windshield.
Cut the adhesive bead all round using the knife supplied to around 1 mm (0.04 in) thickness. |
Installation Procedure |
1. |
Apply primer. |
2. |
Apply adhesive bead.
Cut into the tip of the cartridge in such a way that a bead of adhesive approximately 13 mm (0.5 in) thick is produced. |
3. |
Install windshield into the opening.
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Second mechanic required.
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Insert windshield with
BO-641
suction holder.
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Position using fibre tape.
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4. |
Remove
BO-641
suction holder.
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5. |
Install lower windshield trim strip.
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6. |
Install the plenum water deflector. Refer to
Plenum Water Deflector Replacement
.
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7. |
Install the windshield pillar garnish molding. Refer to
Windshield Side Garnish Molding Replacement
.
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8. |
Install the inside rearview mirror. Refer to
Inside Rearview Mirror Replacement
.
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9. |
Install the front view camera, if equipped. Refer to
Front View Camera Replacement (Object Lens Cleaning)
Front View Camera Replacement (Base)
.
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10. |
Install the windshield outside moisture sensor, if equipped. Refer to
Windshield Outside Moisture and Headlamp Automatic Control Ambient Light Sensor Replacement
.
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11. |
Connect the negative battery cable. Refer to
Battery Negative Cable Disconnection and Connection
.
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12. |
Close the hood.
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