Volume 5, Issue 6        November/December 2003


The Cutting EDGE         new car installations___________
2000-03 Jaguar S-Type (4-Door) 
by Jeff Ritchie and John Duff



In preparation for the windshield replacement, complete the following steps. The mirror and the plastic hub are one piece, so grab the hub and slide the plastic cover downward to remove. The rain sensor is hidden under the plastic hub. Remove the rain sensor by disconnecting the two wires and pulling the two green tabs outward from the side of the bracket. The new windshield had a bracket attached to the glass, so position the rain sensor onto the new bracket and push in the green tabs to hold the sensor into place. 
Remove the side trim by pulling back the rubber door seals exposing four screws. Remove the four screws and lift off the moulding. The top moulding is a wrap-around style with a metal center, so trim off the layover flap, leaving the majority of the moulding on the glass.
Remove the wipers by removing the cap and then the 13-mm nut. To remove the cowl, remove seven caps to expose 7 T-20 Torx screws. Also remove the eight pushpin retainers along bottom edge of the cowl piece. Remove the fitted fender to cowl corner pieces. These corner pieces should be put into place first before installing the cowl. 



The cold knife was used on all four sides. We recommend 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 damage the body paint.



Prime the pinchweld according to your adhesive manufacturer’s specifications. Concentrate only on any areas of the paint that may have been scratched or damaged during the removal process. The freshly cut urethane bed provides the best bonding surface. Allow proper time for the primers to cure. Clean and prime the windshield according to your adhesive manufacturer’s recommendations. 



Dry set the windshield into the opening. There were no setting blocks, so we set the glass with two technicians. We adjusted for proper alignment and made our setting marks along the top of the windshield. Remove the windshield and set it on a cradle with the inboard lite in the upright position. Use a properly cut “V” notch tip to duplicate the original bead size. Apply the adhesive to the glass. Set the windshield top first, using your dry-set marks for proper alignment and being careful not to slide the windshield once it makes contact with the pinchweld. Tape the glass to the roof temporarily until the urethane is cured.



Re-install all parts in reverse order making sure to reconnect and test the rain sensor and the heated wiper park elements. Clean and detail the vehicle.

Jeff Ritchie is a technical training supervisor with the Performance Achievement Group in Madison, Wis., and John Duff is a technician with Auto Glass Specialists Inc. Both are based in Racine, Wis. 

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