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Chrysler PT Cruiser. Manual - part 940

(5) Water test quarter window glass to verify

repair.

(6) Install lower quarter trim, and C& D-Pillar

trim (Fig. 4) and (Fig. 5).

(7) Close liftgate.

WINDSHIELD

DESCRIPTION

Windshields are made of two pieces of glass with a

plastic inner layer. Windshields and selected station-
ary glass are structural members of the vehicle. The
windshield glass is bonded to the windshield frame
with urethane adhesive.

Windshields and other stationary glass protect the

occupants from the effects of the elements. Wind-
shields are also used to retain some airbags in posi-
tion during deployment.

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.

Fig. 6 QUARTER WINDOW GLASS

1 - QUARTER WINDOW GLASS
2 - C-PILLAR

3 - BUTYL
4 - BUTYL RELEASE PAPER

Fig. 5 LOWER QUARTER TRIM

1 - REAR QUARTER PANEL
2 - REAR QUARTER TRIM PANEL
3 - CARGO TIE DOWN QUARTER TRIM LOWER LOOP

23 - 218

STATIONARY GLASS

QUARTER WINDOW (Continued)

RECOMMENDED TOOLS AND ADHESIVE

• Feint Power Cutout Knife

• Equalizert Magnum, Interior Auto Glass Cut

Out Knife

ADHESIVE, PRIMER AND CLEANER

The urethane adhesive holding the windshield to

the opening pinch weld (fence) can be cut using a
sharp cold knife from the exterior of the vehicle.
Using the cold knife method is effective if the wind-
shield is already broken. If the glass must be sal-
vaged, cutting the urethane adhesive from the
interior of the vehicle using a reciprocating or oscil-
lating power knife is recommended.

RECOMMENDED TOOLS AND ADHESIVE

The following urethane adhesive systems are OEM

certified and conform to the FMVSS 212 windshield
retention standard and the FMVSS 216 roof crush
standard.

WARNING

WINDSHIELD SAFETY PRECAUTIONS

WARNING:

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, AND PINCH WELD (FENCE)
PRIMER PROVIDED BY THE ADHESIVE MANUFAC-
TURER. IF NOT, STRUCTURAL INTEGRITY COULD
BE COMPROMISED.
DAIMLERCHRYSLER

DOES

NOT

RECOMMEND

GLASS

ADHESIVE

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.

REMOVAL

REMOVAL - EXTERIOR METHOD

The urethane adhesive holding the windshield to

(1) Remove inside rear view mirror.
(2) Remove windshield wiper arms.
(3) Remove cowl cover.
(4) Place protective covers over instrument panel

and hood.

(5) Remove windshield A-pillar trim and header.
(6) Using a sharp cold knife, cut urethane adhe-

sive holding the windshield to the A-pillars, roof
header and cowl pinch weld fences (Fig. 7). A power
cutting device can be used if available.

(7) Remove windshield from vehicle.

Fig. 7 CUT URETHANE AROUND WINDSHIELD

1 - COLD KNIFE
2 - WINDSHIELD ASSEMBLY WITH ENCAPSULATION

STATIONARY GLASS

23 - 219

WINDSHIELD (Continued)

REMOVAL - INTERIOR METHOD

The urethane adhesive holding the windshield to

(1) Remove inside rear view mirror.
(2) Remove instrument panel top cover, refer to

Instrument Panel.

(3) Remove A-pillar trim.
(4) Place protective covers over instrument panel

and hood.

(5) Using a reciprocating or oscillating power

knife, cut urethane adhesive holding the windshield
to the A-pillars, roof header and cowl pinch weld
fences. Refer to instructions provided with the equip-
ment being used.

(6) Remove windshield from vehicle.

REMOVAL - EXTERIOR METHOD - PT-27 ONLY

The urethane adhesive holding the windshield to

(1) Remove inside rear view mirror.
(2) Remove windshield wiper arms.
(3) Remove cowl cover.
(4) Place protective covers over instrument panel

and hood.

(5) Remove windshield header and A-pillar trim

and header.

(6) Using a sharp cold knife, cut urethane adhe-

sive holding the windshield to the A-pillars, roof
header and cowl pinch weld fences (Fig. 8). A power
cutting device can be used if available.

(7) Remove windshield from vehicle.

REMOVAL - INTERIOR METHOD - PT-27 ONLY

The urethane adhesive holding the windshield to

(1) Remove inside rear view mirror.
(2) Remove instrument panel top cover, refer to

Instrument Panel.

(3) Remove header and A-pillar trim.
(4) Place protective covers over instrument panel

and hood.

(5) Using a reciprocating or oscillating power

knife, cut urethane adhesive holding the windshield
to the A-pillars, roof header and cowl pinch weld
fences. Refer to instructions provided with the equip-
ment being used.

(6) Remove windshield from vehicle.

INSTALLATION

CAUTION: Open the left front door glass before
installing windshield to avoid pressurizing the pas-
senger compartment. If a door is slammed before
urethane bonding is cured, water leaks can result.
Allow the urethane at least 24 hours to cure before
returning the vehicle to use.
To avoid stressing the replacement windshield, the
urethane bonding material on the windshield fence
should be smooth and consistent to the shape of
the replacement windshield. The support spacers
should be cleaned and properly installed on weld
studs or repair screws at bottom of windshield
opening.

Fig. 8 CUT URETHANE AROUND WINDSHIELD

1 - COLD KNIFE
2 - WINDSHIELD ASSEMBLY WITH ENCAPSULATION

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STATIONARY GLASS

WINDSHIELD (Continued)

(1) Verify support spacers in windshield opening. If

not present, install spacers as indicated. (Fig. 10)

(2) Verify squeak tape on roof panel hooks. If not

present, install squeak tape. (Fig. 10) Section C-C.

(3) Verify replacement windshield has squeak tape

and anti-squeak lube. If not present, install squeak
tape and anti-squeak lube. (Fig. 9)

(4) Position windshield into opening by installing

encapsulation locator pin then loading the encapsula-
tion hooks onto the panel hooks. (Fig. 11)

(5) Verify glass encapsulation lays evenly along

roof panel and that there is no gapping of the encap-
sulation squeak tape to the windshield opening. If
gaps are present, the pinch weld fence must be
formed to the shape of the new glass.

(6) Remove replacement windshield from opening.
(7) 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. 12)

WARNING: DO NOT USE SOLVENT BASED GLASS
CLEANER

CLEAN

WINDSHIELD

BEFORE

APPLYING

GLASS

PREP AND

PRIMER.

POOR

ADHESION CAN RESULT.

(8) Clean inside of windshield with ammonia based

glass cleaner and lint-free cloth.

(9) Apply Glass Prep adhesion promoter 25 mm (1

in.) wide around perimeter of windshield and wipe
with clean/dry lint-free cloth until no streaks are vis-
ible.

(10) Apply Glass Primer 25 mm (1 in.) wide

around perimeter of windshield. Allow at least three
minutes drying time.

(11) Apply a bead of urethane on windshield glass

as indicated. (Fig. 12)

(12) With the aid of a helper, position the wind-

shield over the windshield opening and install encap-
sulation locator pin then load encapsulation hooks
onto the roof panel hooks.

(13) Push windshield into opening until no gap

encapsulation lays evenly along roof panel and there
is no gapping of encapsulation squeak tape to the
windshield opening

(14) Clean excess urethane from exterior with

Mopar, Super clean or equivalent.

(15) Apply

tape

windshield

assembly

required if gap exists around windshield opening.

(16) After urethane has cured, remove tape strips

and water test windshield to verify repair.

(17) Install cowl covers.
(18) Install inside rear view mirror.
(19) Allow urethane to cured for 10–12 hours.

Remove tape strips and water test windshield.

Fig. 9 WINDSHIELD INSTALLATION

1- WINDSHIELD ASSEMBLY WITH ENCAPSULATION
2 - ENCAPSULATION SQUEAK REDUCTION TAPE
3 - ANTI-SQUEAK LUBRICANT

Fig. 10 WINDSHIELD SUPPORTS

1 - SUPPORT SPACERS ON ROOF PANEL (9mm X 20mm X
3mm)
2 - SUPPORT SPACERS ON COWL PANEL (9mm X 20mm X
6mm)
3 - ROOF PANEL HOOK
4 - ROOF PANEL SQUEAK REDUCTION TAPE

STATIONARY GLASS

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WINDSHIELD (Continued)

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