SECTION 18: BODY
DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
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From inside of vehicle, remove center post
and interior finishing panels surrounding the
windshield. In this case, we are replacing
the R.H. side windshield.
From outside of vehicle, remove filler
located inside rubber seal to ease damaged
windshield removal.
From inside of vehicle, push against the top
L.H. side corner of windshield for the re-
moval of a R.H. side windshield. If the L.H.
side windshield had to be removed, you
would have to push against the top R. H.
side corner.
NOTE
We are referring to the L.H and R.H. side as
viewed from the inside of the vehicle.
At the same time, another person gradually
lifts the rubber lip from the vehicle exterior
using a plastic spatula from top to bottom.
Remove the entire damaged windshield and
broken glass if applicable.
If applicable, using a screwdriver or metal
rod, remove black butyl sealant residue from
rubber seal then clean with Sika 205.
Windshield Installation
NOTE
Rubber seal may have to be replaced if it was
used on several windshield replacements.
Spray rubber seal with soapy water to
ease windshield insertion.
Insert rope into rubber extrusion leaving
enough length at each corner to make a
loop. Spray soapy water onto rope and
rubber extrusion (Figure 17).
Slide windshield into rubber seal groove
starting with the bottom curved side
edge. Using a plastic spatula, move the
rubber seal lip aside to gradually insert
the windshield into the groove.
Spray soapy water on a regular basis to
ease this operation.
Using the same type of plastic spatula,
repeat the same operation from inside of
vehicle, gradually inserting the wind-
shield into the groove.
FIGURE 17: WINDSHIELD INSTALLATION USING ROPE
NOTE
Make sure windshield bottom edge is well
inserted into the rubber seal groove before
proceeding with the sides.
Then, working from both sides of wind-
shield bottom to top, gradually move the
rubber seal lip aside to insert the wind-
shield into the groove. Use also soapy
water on the inside of vehicle to insert
the windshield into the rubber seal
groove.
Insert the top curved corner then finish
with the top of windshield.
At the top of windshield, clean surface
between fiberglass and rubber extrusion
using Sika 205.
Apply Sika 221 black between fiberglass
and rubber extrusion (Figure 18).
Spray filler and rubber seal groove
generously with soapy water.
Using the special filler insertion tool,
insert the filler into the rubber seal
groove.
Gradually insert filler into the rubber seal
groove ensuring to leave a 2 inch ex-
cess length at the filler extremity.
Every 6 inches or so, it is important to
compress the filler due to its tendency to
contract during drying process.
When filler insertion is almost complete,
cut filler leaving ¼” of excess length to
thwart filler contraction over time then
insert filler into groove.
