Toyota
Jeep Cherokee
 Service Manual
Body » Stationary glass » 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 pinchweld flanges.

REMOVAL

(1) Cover the interior and exterior body surface areas with a protective covering.

(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.

Fig. 1 Cutting Urethane Around Windshield-Typical
Fig. 1 Cutting Urethane Around Windshield-Typical

1 - WINDSHIELD
2 - COLD KNIFE

INSTALLATION-SHORT METHOD

WARNING: REVIEW ALL WARNINGS AND CAUTIONS 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 urethane primer and wipe glass dry after primer application.

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: ² With the molding at room temperature, press the molding onto the windshield corners.

² 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 windshield 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 parallel 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 interior side of the glass (Fig. 4).
  •  Allow the primer to dry for at least 10-12 minutes.

(11) Apply a small amount of adhesive to the bottom 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 immediately 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.

(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.

Fig. 2 Work Surface Set up
Fig. 2 Work Surface Set up

1 - WINDSHIELD AND MOLDINGS
2 - BLOCKS

Fig. 3 Masking Tape Location For Blackout Primer
Fig. 3 Masking Tape Location For Blackout Primer

1 - POSITION TAPE 5/8 INCH FROM EDGE OF GLASS
2 - 1-INCH WIDE MASKING TAPE

INSTALLATION-EXTENDED METHOD

WARNING: REVIEW ALL WARNINGS AND CAUTIONS IN THIS GROUP BEFORE PRECEDING WITH INSTALLATION.

Fig. 4 Blackout Primer Application
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
Fig. 5 Windshield Bottom Support Spacers

1 - SUPPORT SPACERS
2 - WINDSHIELD
3 - SUPPORT SPACER
4 - COWL
5 - MOLDING

(1) Remove the all of urethane from all pinchweld flanges.

Fig. 6 Applicator Nozzle Preparation
Fig. 6 Applicator Nozzle Preparation

1 - CUT NOZZLE THIS SHAPE FOR EXTENDED PROCEDURE
2 - CUT NOZZLE THIS SHAPE FOR SHORT PROCEDURE

(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: ² With the molding at room temperature, press the molding onto the windshield corners.

² 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 pencil (or use masking tape). The marks (or masking tape) will be used for installation alignment reference.

(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 minutes.

(9) Apply a small amount of adhesive to the bottom 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 immediately 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.

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    Jeep Cherokee Service Manual / Body / Stationary glass / Removal and installation / Windshield

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