Place the vehicle in the work area, apply the parking brake and prepare for work: raise the hood, lower the door windows, disconnect the ground wire terminal from the battery (flat-head screwdriver, 10 mm wrench).
Disassemble the interior to remove the windshield glass:
- remove the windshield wiper arms, unscrew the screws securing the windshield frame trims, remove the trims (spanner 13, screwdriver Torx T20);
- remove windshield pillar trims (flat head screwdriver);
- remove the interior rear view mirror (flat head screwdriver);
- unscrew two screws and remove the sun visors with holders (phillips screwdriver);
Disassemble the interior to remove the side windows:
- fold back the rear seat;
- remove the covers of the upper mounting bolts of the rear side seat belts, unscrew the bolts (replacement head 17, ratchet);
- remove the rear pillar trims (torx T20 screwdriver, flat head screwdriver).
For the left loading door, remove the windshield wiper arm.
Protect the paintwork of the body in the area adjacent to the glass from damage when cutting the adhesive seam, as shown in Figure 16-1 (adhesive tape).
Removal
Pierce the adhesive seam and pass a twisted wire saw through the pierced 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 piercing, twisted wire saw TU 64-1-749-80 or ZEPK 05 holder according to catalog f. Henkel, 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).
Operations to cut the adhesive seam and remove glass should be performed with an assistant.
Figure 16-1 - Device for cutting adhesive joints of car windows: 1 - wire saw L=300...500 mm; 2 - car window glass; 3 - saw handle; 4 - adhesive seam; 5 - car body; 6 - adhesive tape
Installation
Prepare the surfaces to be glued (the technological sequence of operations for preparing surfaces is shown using the example of the adhesive system from the company "Terozon").
Check the size of the gaps around the perimeter where the windshield meets the windshield frame. The check is carried out using a technological windshield. The gap size should be no more than 2 mm (set of feeler gauges). If necessary, make adjustments to the window opening (set of straightening tools).
Place the removed or new glass with the suction cup holders on the work table with the outer surface facing down (table type BS-152 with 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 process of cutting glass, there are areas of the window opening that are exposed to the metal, degrease these areas, then apply primer to the degreased surfaces. Allow the soil to dry for 15 minutes in natural conditions (white spirit, wiping cloth, primary primer, brush).
Apply enamel primer to the primed edges of the window opening (from the adhesive system delivery set), avoiding the primer getting on the remains of 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 16-5, 16-6, 16-8, 16-10 with a thickness of: for the windshield and loading door glass - 3+1 mm; for side windows - 6+1 mm.
If new glass is installed, treat the perimeter of the glass with a cleaner (from the adhesive system delivery set) or isopropyl alcohol, then apply glass primer (from 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 16-7, 16-9, 16-11, 16.12. 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 and put the supplied tip on the tube (firmware technology). If the tip of the glue tube requires preparation, prepare it for use as shown in Figure 16-2 (technological knife, ruler). Place the tube of glue into the syringe gun.
Figure 16-2 - Tube tip cutting diagram
Apply the adhesive to the glass with a uniform, continuous bead of triangular cross-section, as shown in Figure 16-3, over the applied primer (metal ruler, syringe gun, adhesive from the Monopac Evolution, SP Kit, Bipac Evolution glass bonding kit or Tsrostat UHV/M or Betasil 1701 adhesive).
Figure 16-3 - Shape of the adhesive bead before installation on the body
It is permissible to apply glue to the flange of the window opening.
Adhesive consumption rate per car: for windshield - 400 ml; for glass of the left loading door - 150 ml, for glass of the right loading door - 100 ml; for side glass - 150 ml.
Make sure that the holders, Figure 16-4, are securely fastened to the glass. Install the glass in 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 for the applied adhesive before installing the glass on the body is 15...20 minutes.
Figure 16-4 - Installing glass using holders
Press the glass evenly and carefully against the opening, ensuring that the adhesive bead is evenly pressed.
Attention:
- it is prohibited to mix materials of different adhesive systems;
- it is prohibited to use materials after the expiration date;
- reducing the thickness of the adhesive between the glass and the body less than specified is unacceptable, as this leads to cracking of the glass during operation;
- the presence of glue on the front surfaces of the body and glass is not allowed. If necessary, remove excess glue (rags, white spirit);
- glass installation operations should be performed with an assistant;
- optimal glue polymerization mode: air temperature 23°C, humidity 50%, at lower 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, it is prohibited to move the car or close the doors sharply for 7-8 hours after installing the glass. Keep the door glass open to prevent air pressure from being applied to the glass when the door is closed. Work involving applying force to the glass can begin 14 hours after gluing. The optimum strength of the adhesive bond is achieved, depending on weather conditions, after 4-6 days.
Check the car for leaks. To do this, it is necessary to pour a stream of water over the adhesive seam of the installed glass (hose washer). Leakage along the adhesive joint is not allowed.
Install upholstery, trim and other parts removed from the vehicle in the reverse order of removal. Clean the glass on both sides (rags, isopropyl alcohol or the cleaner from the package).
Figure 16-5 - Scheme of gluing spacers to the windshield opening: 1 - windscreen spacer
Figure 16-6 - Section at the place of gluing the windshield spacers: 1 - glass; 2 - windshield spacer; 3 - adhesive seam; 4 - car body
Figure 16-7 - Scheme of applying adhesive seam to windshield glass: 1 - adhesive seam; 2 - windshield glass
Figure 16-8 - Scheme of gluing spacers to the side window opening: 1 - side window spacer
Figure 16-9 - Scheme of applying the adhesive seam to the side window glass: 1 - adhesive seam; 2 - side window glass
Figure 16-10 - Scheme of gluing spacers on the loading door window openings: 1 - Remote gasket for loading door windows
Figure 16-11 - Scheme of applying the adhesive seam to the glass of the left loading door window: 1 - adhesive seam; 2 - glass of the left loading door window
Figure 16-12 - Scheme of applying the adhesive seam to the glass of the right loading door window: 1 - adhesive seam; 2 - glass of the loading door window on the right