Orlando

Windscreen Replacement

Special Tools

For equivalent regional tools, refer to Special Tools .

Warning: Refer to Cracked Window Warning in the Preface section.

Warning: Refer to Glass and Sheet Metal Handling Warning in the Preface section.

1. Position the vehicle on level ground and move the front wheels to the straight-ahead position.
2. Disconnect the battery negative connection. Refer to Battery Negative Cable Disconnection and Connection : without Start/Stop System
3. Remove the air inlet grille panel. Refer to Air Inlet Grille Panel Replacement .
4. Remove the inside rearview mirror. Refer to Inside Rearview Mirror Replacement .
5. Remove the remote control door lock receiver. Refer to Remote Control Door Lock Receiver Replacement .
6. Remove the windscreen outside moisture sensor. Refer to Windscreen Outside Moisture Sensor Replacement .



7. Use BO-46974 removal system .

Warning: Refer to Defroster Outlet Warning in the Preface section.

8. Take the diagonal measurement (1) of the windscreen.
9. Cut cutting wire into four times lengths.

Approx. 6400 mm (251.9677 in), the circumference of the corresponding roll of wire is about 1000 mm (39.369 in).




10. Heat the awl with a suitable tool.

Note: Ensure that the windscreen is not damaged in the process, otherwise stress cracks in the windscreen may occur.

11. Stick the awl (1) with adhesive bed in the area of the front wall.
12. Pull the wire through.

•	Thread the cutting wire into the hole of the awl and bend it over.

•	Pull the cutting wire with the awl to the middle of the steering wheel in the interior.





Note: The cutting wire (1) should be rolled in beneath the rubber window seal (2) at the windscreen.

13. Lay the wire under the windscreen all the way round.



14. Pull the second wire end through.

•	Stick awl approx. 1 cm (0.393 in) overlapping the first entry place with adhesive bed.

•	Thread the cutting wire into the hole of the awl and bend it over.

•	Pull the rest of the wire into the interior with the awl.





Note: Ensure that the cutting wire is fitted correctly to the winch deflection roller.

15. Place the winch with two winding heads (2) on windscreen inside.

•	Position winch in right-hand area of the windscreen.

•	Attach the cutting wire to the winch.

Note: In the area of the A-pillar/front wall, increased cutting effort must be made.

16. Cut out windscreen.

•	Use the plastic sheet for the protection of the armature board.

•	Arrow shows the path taken by the cutting wire (1).

•	Insert transfer ratchet and pre-tension cutting wire.

•	Cut out the windscreen until the cutting wire is level with the winch.





Note: Ensure that the cutting wire is fitted correctly to the winch deflection roller.

17. Place the winch with two winding heads (2) in the vehicle.

•	Position the winch near to the interior rear view mirror.

•	Insert transfer ratchet and pre-tension cutting wire.

Note: In the area of the A-pillar/roof frame, increased cutting effort must be made.

18. Cut out windscreen.

•	Use the hold-down positioner and the plastic sheet to protect the sunroof.

•	Arrow shows the path taken by the cutting wire (1).

•	Cut out the windscreen until the cutting wire is level with the winch.





Note: Ensure that the cutting wire is fitted correctly to the winch deflection roller.

19. Place the winch with one winding head in the vehicle.

•	Position the winch with one winding head on the A-pillar on the driver's side (2).

•	Attach the cutting wire (1) to the winch.

•	Insert transfer ratchet and pre-tension cutting wire.

Note: Use lubricant on the winch deflection roller. More pulling force is required to cut the area around the A-pillar/bulkhead.

Arrow shows the path taken by the cutting wire.
20. Cut out windscreen.

•	Cut out the windscreen until the cutting wire is level with the winch.

•	Use the plastic sheet for the protection of the armature board.





Note: Ensure that the cutting wire is fitted correctly to the winch deflection roller.

21. Place the winch with one winding head in the vehicle.

•	Position the winch with one winding head in the area of the roof frame (1).

•	Insert transfer ratchet and pre-tension cutting wire (2).

Note: Use lubricant on the winch deflection roller. More pulling force is required to cut the area around the A-pillar/roof frame.

Arrow shows the path taken by the cutting wire.
22. Cut out windscreen.

•	Cut out the windscreen until the cutting wire is level with the winch.

•	Use the plastic sheet for the protection of the ceiling.




23. Position both cutting tools.

•	Shift winch with two winding heads downwards (1).

•	Shift the winch with one winding head (2) in the ceiling area so that the cutting wire (3) is crossed.

•	Insert transfer ratchet and pre-tension cutting wire.

Note: Arrow shows the path taken by the cutting wire.

24. Cut out windscreen.

•	Cut out windscreen until the cutting wire has cut through the adhesive bed completely.

•	Use the plastic sheet for the protection of the ceiling.

25. Remove glass removal system.
26. Fit and lockBO-641 holder to windscreen.

Note: Second mechanic required.

27. Remove windscreen.
28. Remove the windscreen upper reveal moulding. Refer to Windscreen Upper Reveal Moulding Replacement .



29. Cut out the adhesive tape with the knife provided (1) to within 1 mm (0.039 in).
30. Repair any paint damage.

Using a touch-up pen to match the colour of the vehicle, repair any paint damage.

31. Cut off the adhesive bead on the glass pane

Cut out the adhesive tape with the knife provided (1) to within 1 mm (0.039 in).

1. Remove all mounds or loose pieces of urethane adhesive from the pinch-weld area.
2. Inspect for any of the following problems in order to help prevent future breakage of the window:

•	High weld.

•	Solder spots.

•	Hardened sealer.

•	Any other obstruction or irregularity in the pinch-weld flange.

3. After repairing the opening as indicated, perform the following steps:

Remove all traces of broken glass from the outer cowl panel, seats, floor, and defroster ducts.




4. Apply adhesive bead.

Cut into the tip of the cartridge in such a way that a bead of adhesive approx. 13 mm (0.511 in) thick is produced.

5. Install the windscreen upper reveal moulding. Refer to Windscreen Upper Reveal Moulding Replacement .
6. Insert windscreen.

•	Place the windscreen on the roof frames and lower down.

•	Insert windscreen with BO-641 holder.

7. Secure windscreen in position with fabric tape.
8. Second mechanic required.
9. Clean any excess urethane adhesive from the body.
10. Use a soft spray of warm water in order to immediately water test the window.
11. Inspect the window for leaks.
12. If any leaks are found, use a plastic paddle in order to apply extra urethane adhesive at the leak point.
13. Retest the window for leaks.
14. Maintain the following conditions in order to properly cure the urethane adhesive:

•	Partially lower a door window in order to prevent pressure buildups when closing doors before the urethane adhesive cures.

•	Do not drive the vehicle until the urethane adhesive is cured. Refer to the above curing times.

•	Do not use compressed air in order to dry the urethane adhesive.

15. Install the windscreen outside moisture sensor. Refer to Windscreen Outside Moisture Sensor Replacement .
16. Install the remote control door lock receiver. Refer to Remote Control Door Lock Receiver Replacement .
17. Install the inside rearview mirror. Refer to Inside Rearview Mirror Replacement .
18. Install the air inlet grille panel. Refer to Air Inlet Grille Panel Replacement .
19. Connect the battery negative connection. Refer to Battery Negative Cable Disconnection and Connection : without Start/Stop System .