Jeep XJ. Manual — part 474
STATIONARY GLASS
TABLE OF CONTENTS
page
page
DESCRIPTION AND OPERATION
WINDSHIELD SAFETY PRECAUTIONS . . . . . . . . . 6
REMOVAL AND INSTALLATION
WINDSHIELD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
REAR DOOR STATIONARY WINDOW GLASS . . . . 9
REAR QUARTER WINDOW GLASS . . . . . . . . . . . 10
LIFTGATE GLASS . . . . . . . . . . . . . . . . . . . . . . . . 11
DESCRIPTION AND OPERATION
WINDSHIELD SAFETY PRECAUTIONS
DESCRIPTION
WARNING: DO
NOT
OPERATE
THE
VEHICLE
WITHIN 24 HOURS OF WINDSHIELD INSTALLATION.
IT TAKES AT LEAST 24 HOURS FOR URETHANE
ADHESIVE TO CURE. IF IT IS NOT CURED, THE
WINDSHIELD MAY NOT PERFORM PROPERLY IN
AN ACCIDENT.
URETHANE ADHESIVES ARE APPLIED AS A SYS-
TEM. USE GLASS CLEANER, GLASS PREP SOL-
VENT, GLASS PRIMER, PVC (VINYL) PRIMER AND
PINCH WELD (FENCE) PRIMER PROVIDED BY THE
ADHESIVE MANUFACTURER. IF NOT, STRUCTURAL
INTEGRITY COULD BE COMPROMISED.
DAIMLERCHRYSLER DOES NOT RECOMMEND
GLASS
ADHESIVE
BY
BRAND.
TECHNICIANS
SHOULD REVIEW PRODUCT LABELS AND TECHNI-
CAL DATA SHEETS, AND USE ONLY ADHESIVES
THAT THEIR MANUFACTURES WARRANT WILL
RESTORE A VEHICLE TO THE REQUIREMENTS OF
FMVSS 212. TECHNICIANS SHOULD ALSO INSURE
THAT PRIMERS AND CLEANERS ARE COMPATIBLE
WITH THE PARTICULAR ADHESIVE USED.
BE SURE TO REFER TO THE URETHANE MANU-
FACTURER’S
DIRECTIONS
FOR
CURING
TIME
SPECIFICATIONS, AND DO NOT USE ADHESIVE
AFTER ITS EXPIRATION DATE.
VAPORS THAT ARE EMITTED FROM THE URE-
THANE ADHESIVE OR PRIMER COULD CAUSE
PERSONAL INJURY. USE THEM IN A WELL-VENTI-
LATED AREA.
SKIN
CONTACT
WITH
URETHANE ADHESIVE
SHOULD BE AVOIDED. PERSONAL INJURY MAY
RESULT.
ALWAYS WEAR EYE AND HAND PROTECTION
WHEN WORKING WITH GLASS.
CAUTION: Protect all painted and trimmed surfaces
from coming in contact with urethane or primers.
Be careful not to damage painted surfaces when
removing moldings or cutting urethane around
windshield.
OPERATION
The windshield is attached to the window frame
with urethane adhesive. The urethane adhesive is
applied cold and seals the surface area between the
window opening and the glass. The primer adheres
the urethane adhesive to the windshield.
It is difficult to salvage a windshield during the
removal operation. The windshield is part of the
structural support for the roof. The urethane bonding
used to secure the windshield to the fence is difficult
to cut or clean from any surface. If the moldings are
set in urethane, it would also be unlikely they could
be salvaged. Before removing the windshield, check
the availability of the windshield and moldings from
the parts supplier.
REMOVAL AND INSTALLATION
WINDSHIELD
The windshield is positioned in the reveal molding
and is bonded to the windshield frame with urethane
adhesive.
Depending on the circumstances, either one of two
windshield glass installation methods can be used:
• The short method.
• The extended method.
The short method is used when the windshield
glass is removed intact, and the body opening and
the pinchweld flanges do not require repair.
The extended method must be used when the body
opening or a flange is damaged. The extended
method must also be used when urethane no longer
adheres to either the windshield glass or the pinch-
weld flanges.
REMOVAL
(1) Cover the interior and exterior body surface
areas with a protective covering.
23 - 6
BODY
XJ
(2) Remove the windshield wiper arms and the
rearview mirror.
(3) Using a razor knife, slide the blade between
the windshield glass and the inboard edge of the
reveal molding.
(4) Cut around the interior perimeter of the reveal
molding and sever the cap of the reveal molding.
(5) Using a cold knife, cut the urethane around the
perimeter of the windshield (Fig. 1).
(6) Remove the windshield glass from the frame.
INSTALLATION—SHORT METHOD
WARNING: REVIEW ALL WARNINGS AND CAU-
TIONS IN THIS GROUP BEFORE PRECEDING WITH
INSTALLATION.
(1) Trim the urethane from the pinchweld flanges.
Leave a 3 mm (0.1 in.) level base of urethane on the
pinchweld flanges.
WARNING: DO NOT USE SOLVENT BASED GLASS
CLEANER
TO
CLEAN
WINDSHIELD
BEFORE
APPLYING
GLASS
PREP AND
PRIMER.
POOR
ADHESION CAN RESULT.
(2) Clean inside of windshield with ammonia based
glass cleaner and lint-free cloth.
(3) Prime outer perimeter of interior side of glass
16 mm (5/8 inch) from edge. Use a wipe-off type ure-
thane primer and wipe glass dry after primer appli-
cation.
NOTE: The reveal molding has an adhesive applied
to the windshield contact surface to help secure the
molding to the windshield during the installation
procedure.
(4) Apply the molding to the windshield:
• With the molding at room temperature, press
the molding onto the windshield corners.
• From corner to corner, work the molding to the
center of each side. (Some stretching of the molding
may be required during this procedure.)
(5) Place the glass on the pinchweld flanges and
inspect for gaps in the urethane. Gaps in excess of 3
mm (1/8 inch) must be filled with urethane.
(6) Adjust windshield glass position until it is
aligned with the flanges and adhesive.
(7) Using a grease pencil or equivalent, make
alignment marks on the glass and body.
(8) Remove replacement windshield from wind-
shield opening.
(9) Position the windshield inside up on a suitable
work surface with two padded, wood 10 cm by 10 cm
by 50 cm (4 in. by 4 in. by 20 in.) blocks, placed par-
allel 75 cm (2.5 ft.) apart (Fig. 2).
CAUTION: Avoid spilling or dripping primer on
painted surfaces. Clean spills or drips immediately.
The primer will damage the paint if it remains on
the surface for any length of time.
(10) If the replacement windshield glass does not
have blackout primer:
• Attach a 25 mm (1 in) wide masking tape band
around the interior side of the glass 16 mm (5/8 in)
from the edge of the glass (Fig. 3).
• Do not attach tape along the bottom of the glass
and attach it only to the inside of the glass.
• Clean the 16-mm (5/8-in) wide surface area
around the glass with isopropyl alcohol.
• Thoroughly mix and apply glass blackout primer
to the 16 mm (5/8 in) surface area around the inte-
rior side of the glass (Fig. 4).
• Allow the primer to dry for at least 10-12 min-
utes.
(11) Apply a small amount of adhesive to the bot-
tom support spacers and attach the support spacers
to the bottom of the windshield, 170 mm inboard
from the outer windshield edge (Fig. 5).
(12) Cut the urethane adhesive applicator nozzle
(Fig. 6).
CAUTION: Be prepared to install the glass immedi-
ately after applying the adhesive, as the adhesive
will begin to cure in less than 10 minutes.
(13) Apply a continuous, 6-mm (1/4-in) diameter
bead of urethane adhesive to the surface area.
(14) Align the glass with the reference marks and
position the glass on the pinchweld flanges. Ensure
that the windshield glass is correctly seated on the
support spacers.
Fig. 1 Cutting Urethane Around Windshield—Typical
1 – WINDSHIELD
2 – COLD KNIFE
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BODY
23 - 7
REMOVAL AND INSTALLATION (Continued)
(15) Force the windshield glass inward just enough
to wet-out and set the urethane. Use care to avoid
excessive squeeze-out of adhesive.
(16) Water test the windshield with a water spray
after
installation.
Do
not
direct
high
pressure
streams of water directly at urethane. If any leaks
are detected, apply urethane as necessary.
(17) If used, remove the masking tape from the
inner surface of the glass.
(18) Install all components and clean the vehicle.
(19) Open the vehicle windows to prevent interior
pressure while the urethane is curing. If not
vented, pressure in the interior of the vehicle
may interfere with proper glass bonding.
(20) Install the rearview mirror.
INSTALLATION—EXTENDED METHOD
WARNING: REVIEW ALL WARNINGS AND CAU-
TIONS IN THIS GROUP BEFORE PRECEDING WITH
INSTALLATION.
(1) Remove the all of urethane from all pinchweld
flanges.
Fig. 2 Work Surface Set up
1 – WINDSHIELD AND MOLDINGS
2 – BLOCKS
Fig. 3 Masking Tape Location For Blackout Primer
1 – POSITION TAPE 5/8 INCH FROM EDGE OF GLASS
2 – 1-INCH WIDE MASKING TAPE
Fig. 4 Blackout Primer Application
1 – APPLY PRIMER TO THIS AREA OF GLASS
2 – BLACKOUT PRIMER APPLICATOR
3 – TAPE
Fig. 5 Windshield Bottom Support Spacers
1 – SUPPORT SPACERS
2 – WINDSHIELD
3 – SUPPORT SPACER
4 – COWL
5 – MOLDING
23 - 8
BODY
XJ
REMOVAL AND INSTALLATION (Continued)
(2) Inspect and repair the windshield opening and
pinchweld flanges.
(3) Prime the pinchweld flanges with a urethane
base primer. However, if the flange is color-coated
with paint, prime the flanges with a paint finish
primer. This is important because urethane
adhesive
will
not
adhere
to
all
color-coat
paints. Allow primer sufficient time to dry.
NOTE: The reveal molding has an adhesive applied
to the windshield contact surface to help secure the
molding to the windshield during the installation
procedure.
(4) Apply the reveal molding to the windshield:
• With the molding at room temperature, press
the molding onto the windshield corners.
• From corner to corner, work the molding to the
center of each side. (Some stretching of the molding
may be required during this procedure).
(5) Install and inspect the fit of the windshield on
the pinchweld flanges as follows:
• Position windshield until it is aligned within
windshield opening.
• Measure the gap between the pinchweld flanges
and glass around perimeter of the glass and flange.
• The reveal molding should equally cover the
A-Pillars on both sides.
• The flanges should also extend above the glass
edge equally around the perimeter of the opening.
(6) If the pinchweld flanges require repair, remove
the windshield glass and straighten, align, or repair
the flange(s) as necessary.
(7) Position the windshield in the opening and
inspect the windshield fit again. Mark the windshield
final position on the glass and body with a wax pen-
cil (or use masking tape). The marks (or masking
tape) will be used for installation alignment refer-
ence.
(8) If the replacement windshield does not have
blackout primer:
• Attach a 25-mm (1-in) wide masking tape band
around the interior side of glass 16 mm (5/8 in) from
edge of glass (Fig. 3).
• Do not attach tape along the bottom of the glass
and attach only to the inside of glass.
• Thoroughly mix and apply blackout primer to
the 16 mm (5/8 in) surface area around the interior
side of the glass (Fig. 4).
• Allow the primer to dry for at least 10-12 min-
utes.
(9) Apply a small amount of adhesive to the bot-
tom support spacers and attach the support spacers
to the bottom of the windshield, 170 mm inboard
from the outer windshield edge (Fig. 5).
(10) Cut the urethane applicator nozzle (Fig. 6).
(11) Apply a continuous bead of urethane to the
surface area with blackout primer on the interior
side of glass. The bead should be 9-mm (3/8-in) wide
by 12.7-mm (1/2-in) deep for best results.
CAUTION: Be prepared to install the glass immedi-
ately after applying the adhesive, as the adhesive
will begin to cure in less than 10 minutes.
(12) Align the windshield with the wax pencil
installation alignment reference marks (or the tape
strips). Position the windshield on pinchweld flanges
and spacers.
(13) Force the windshield inward just enough to
wet-out and set the urethane. Use care to avoid
excessive squeeze-out of adhesive.
(14) Water test the windshield with a water spray
after
installation.
Do
not
direct
high
pressure
streams of water directly at the urethane. If any
leaks are detected, apply urethane as necessary.
(15) If used, remove the masking tape from the
inner surface of glass.
(16) Install all components and clean the vehicle.
If necessary, refer to the installation procedures.
(17) Open the vehicle windows to prevent interior
pressure while the urethane adhesive is curing. If
not vented, pressure in the interior of vehicle
will interfere with glass bonding.
(18) Install the rearview mirror on the bracket.
REAR DOOR STATIONARY WINDOW GLASS
REMOVAL
The rear door stationary window glass is bonded to
the division bar and is serviced as an assembly.
(1) Lower the window glass.
(2) Remove the inner and outer beltline weather-
strip.
Fig. 6 Applicator Nozzle Preparation
1 – CUT NOZZLE THIS SHAPE FOR EXTENDED PROCEDURE
2 – CUT NOZZLE THIS SHAPE FOR SHORT PROCEDURE
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BODY
23 - 9
REMOVAL AND INSTALLATION (Continued)
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