Prepare the vehicle to perform the work. Disconnect the negative cable from the battery
Disassemble the interior to remove the windshield glass:
- - remove the windshield wiper arms, unscrew the screws securing the windshield frame trims, remove the trims (13 spanner, T20 Torx screwdriver);
- - remove the windshield pillar trims (flathead screwdriver);
- - remove the interior rearview mirror (flathead screwdriver);
- - unscrew two screws and remove the sun visors with holders (Phillips screwdriver);
Disassemble the interior to remove the side windows:
- - fold down the rear seat backs;
- - remove the trims of the upper fastenings of rear side seat belts, unscrew bolts (replaceable head 17, ratchet);
- - remove upholstery of rear pillars (Torx screwdriver T20, flat screwdriver).
For left loading door, remove windshield wiper arm.
Protect the paintwork of the car body in the area adjacent to the glass from damage when cutting the adhesive seam, as shown in Figure 1 (adhesive tape).
Removal
Puncture the adhesive seam and pass a twisted wire saw through the punctured hole, cut the adhesive seam or cut the adhesive seam with a vibrating electric (pneumatic) knife with a cutting part length of 45-55 mm (technological firmware, twisted wire saw TU 64-1-749-80 or ZEPK 05 holder according to the Henkel catalog, or a vibrating pneumatic knife of the USAG type, Italy, or a vibrating electric knife of the FEIN type model 53602, Germany).
Remove the glass from the opening (holders - suction cups).
Cutting off the adhesive seam and removing the glass should be performed with an assistant.
Installation
Prepare the surfaces to be glued (the technological sequence of operations for preparing the surfaces is shown using the example of the adhesive system of the company "Terozon").
Check the size of the gaps along the perimeter of the windshield adjoining the windshield frame.
Check using a technological windshield glass. The gap size should be no more than 2 mm (feeler set).
If necessary, straighten the window opening (straightening tool set).
Put the removed or new glass with suction cup holders on the work table with the outer surface down (BS-152 table with a felt or linoleum covering).
Evenly cut off the remaining adhesive seam on the window frame and the removed glass, leaving a layer 1-2 mm thick (technological knife or vibroelectric (pneumatic) knife with a shortened cutting part of the knife (16-18 mm).
If during the cutting of the glass there are areas of the window opening exposed to the metal, degrease these areas, then apply primer to the degreased surfaces.
Allow the primer to dry for 15 minutes under natural conditions (white spirit, wiping cloth, primary primer, brush).
Apply enamel primer (from the adhesive system delivery set) to the primed edges of the window opening, avoiding the primer getting on the remains of the old glue and on the front surfaces of the body.
Dry the applied primer for at least three minutes under natural conditions.
Degrease the layer of old glue with isopropyl alcohol.
To ensure the required thickness of the adhesive seam, install spacers in the places indicated in Figures 5, 6, 8,10 with a thickness of: for the windshield and loading door glass - 3+1 mm; for side windows – 6+1 mm.
If installing a new glass, treat the perimeter of the glass with a cleaner (included in the adhesive system delivery set) or isopropyl alcohol, then apply a glass primer (included in the adhesive system delivery set) along the edge of the glass in a strip 18-20 mm wide at the place where the glue is applied, in accordance with the diagrams shown in Figures 7, 9, 11, 12.
After applying the primer, dry the coating for at least three minutes under natural conditions.
Degrease the edge of the edging adjacent to the adhesive seam and install the edging on the lower end of the windshield, ensuring a tight fit of the edging to the glass (white spirit or degreaser from the delivery set).
Puncture the outlet hole in the tube, put the supplied tip on the tube (technological firmware).
If the tip of the glue tube requires preparation, then prepare it go to work, as shown in Figure 2 (technological knife, ruler). Install the tube of glue into the syringe gun.
Apply glue to the glass in a uniform, continuous bead of triangular cross-section, as shown in Figure 3, over the applied primer (metal ruler, syringe gun, glue from the Monopac Evolution, S-P Kit, Bipac Evolution glass bonding kit or Terostat UHV/M or Betasil 1701 glue).
It is allowed apply glue to the window opening flange.
The glue consumption rate for one car: for the windshield - 400 ml; for the glass of the left loading door - 150 ml, for the glass of the right loading door - 100 ml; for the side glass - 150 ml.
Make sure that the holders, Figure 4, are securely fastened to the glass. Install the glass on the window opening, ensuring a uniform gap between the end of the glass and the car body around the perimeter.
The maximum permissible holding time of the applied glue before installing the glass on the car body is 15…20 minutes.
Evenly and carefully press the glass to the opening, ensuring uniform crushing of the adhesive bead.
Attention:
- - it is prohibited to mix materials of different adhesive systems;
- - it is prohibited to use materials after the expiration date;
- - a decrease in the thickness of the glue between the glass and the car body, less than specified, is unacceptable, as this leads to a crack in the glass during operation;
- - the presence of glue on the front surfaces of the car body and glass is not allowed. If necessary, remove excess glue (rag, white spirit);
- - perform glass installation operations with an assistant;
- - optimal glue polymerization mode: air temperature 23°C, humidity 50%, at low temperature and humidity, the glue polymerization time increases.
To prevent the glass from “sliding” down, secure it to the body with three pieces of adhesive tape 250 - 300 mm long.
To avoid glass displacement, do not move the car or close the doors sharply for 7 ... 8 hours after installing the glass.
Keep the lowering door windows open so that air pressure does not arise on the glass when closing the doors.
Work associated with applying force to the glass can be started 14 hours after gluing. The optimum strength of the adhesive bond is achieved, depending on weather conditions, in 4-6 days.
Fig. 5. Scheme of gluing spacers on the windshield opening
Fig. 6. Section at the place of gluing the spacers of the windshield
Fig. 7. Scheme of applying the adhesive seam to the windshield glass
Fig. 8. Scheme of gluing spacers on the side window opening
Fig. 9. Scheme of applying the adhesive seam to the side window glass
Fig. 10. Scheme of gluing spacers on the loading door window openings
Fig. 11. Scheme of applying the adhesive seam to the glass of the left loading door window
Fig. 12. Scheme of applying the adhesive seam to the glass of the right loading door window
Check the car for leaks. To do this, it is necessary to flush the adhesive seam of the installed glass with a stream of water (hose wash).
Leaks along the adhesive seam are not allowed.
Install the upholstery, trim and other parts removed from the car in the reverse order of removal.
Clean the glass on both sides (rag, isopropyl alcohol or cleaner from the delivery set).