Supplement, March/April 2000

The CuttingEDGE
new car installations


Windshield Replacement for the
2000 Jaguar XJ-8 Vanden Plas

by Steve Coyle

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1. Getting started:

In preparation for the windshield replacement, pry off the break away style mirror. This vehicle is equipped with a single wiper. Lift the cover, unplug the washer hose, and remove the 17 mm nut that secures the wiper arm. Remove five T20 Torx screws from the cowl panel and remove the cowl. Remove the chrome insert from the top and sides of the rubber moulding with a small screwdriver or plastic paddle. Once the chrome inserts have been removed, pull the rubber moulding away from the glass and body.

 2. Removing the original windshield:

Use a cold knife with a 3/4-inch blade to cut the adhesive along the top and sides, and a 11/2-inch blade for the bottom. A power cut-out tool can also be used. PAG recommends using the full cut-out method. Using a sharp chisel or utility knife, remove the adhesive, leaving a thin skin of well-bonded urethane on the pinchweld. Be careful not to disturb the body paint.

3. Preparing for the new windshield:

Prime the pinchweld according to adhesive manufacturer’s specs. Concentrate only on areas of the paint that may have been scratched or damaged during glass removal. The freshly cut urethane bed provides the best bonding surface. Allow primers time to cure properly. Clean and prime windshield according to manufacturer’s recommendations. Place the rubber moulding onto the glass’ edge. Insert the chrome insert, outer edge first, pinching the rubber moulding and pushing the insert into the groove. Then, insert the inner edge by using a hook tool to lift the lip of the rubber moulding allowing the chrome insert to be seated under the edge of the rubber moulding.

4. Placement of the new windshield:

Dry set the windshield into the opening; adjusting for proper alignment. There are no setting blocks. The rubber moulding sits on the metal edge under the cowl. Remove the windshield and set it on a cradle with the inboard lite upright. Use a properly cut “V” notch tip to duplicate original bead size. Apply a high viscosity, two-part adhesive to the glass along the edge of the rubber moulding on the top and sides, and slightly above the rubber moulding along the bottom. Set the windshield into the opening using your dry set marks to properly align. Be careful not to slide the windshield once it makes contact with the pinchweld. This installation could be a two-man set. Bring the glass over the hood, open hood, and set the top first. Apply pressure to assure proper seal. Check installation with leak detector.

 5. Finishing Touches:

Reinstall cowl and wiper in reverse order of removal. Reattach the washer hose. Test wiper operation. Clean and prep the vehicle.


Reports from the field

Always wear eye, hand and wrist protection while working on the vehicle. This vehicle is equipped with dual airbags and requires additional cure time before releasing to the owner. The Performance Achievement Group (PAG) recommends rapid curing two-part high viscosity urethane for passenger side airbag equipped vehicles. Inform the vehicle owner of cure time and other additional precautions before installation. Always return the vehicle to manufacturer’s specifications. Protect the interior and exterior of the vehicle to prevent damage.

 Steve Coyle is part of the Performance Achievement Group, an auto glass training company in Madison, Wis.


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