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2010 Porsche Cayenne

 2010 Porsche Cayenne.

Windshield removal and replacement instructions

Vehicle type: Four-door utility vehicle

NAGS numbers*: Windshield part numbers FW03287GYY solar, with third visor frit, acoustic interlayer, pre-applied adhesive system, and rain/light sensor; FW03288GYY solar, heated, with third visor frit, acoustic interlayer, PAAS, and rain/light sensor; and FW03289GYY solar coated, heated, with third visor frit, acoustic interlayer, PAAS, and rain/light sensor.

Helpful tools or supplies: New gel pad for the rain sensor. This windshield also might require a second person to help set it, or a portable setting tool if a helper is unavailable. There are no gravity stops, nor a place to attach a temporary one. An aftermarket molding might also be necessary to hide the primed marks on the windshield.

A. Windshield

1. Cover the front seats, floorboards, dash and steering wheel with a clean drop cloth or disposable plastic covers. Note: Always wear eye and hand protection when working with glass. Make sure you have the right glass and moldings, and that the urethane systems you are about to use are current. Windshield part numbers are FW03287GYY, FW03288GYY and FW03289GYY.

2. Drape the fender with a fender cover and tape up any vulnerable areas on the vehicle to protect against possible damage. Tape up the defroster vents to prevent debris from falling into the openings.

3. This vehicle was equipped with a rain sensor and GPS antenna mounted to a bracket attached to the glass. Before beginning windshield removal, make sure the rain sensor and GPS system are operating correctly. Close the hood, windows and doors before checking operation.

4. Remove the lower, two-piece decorative cover that surrounds the rearview mirror base.

5. Twist off the rearview mirror from its mounting, in a clockwise direction.

6. Remove the upper, one-piece decorative cover using a small slot screwdriver to carefully pry it downward. You will see two wiring connectors: one is attached to the rain sensor, and the other to the GPS chip.

7. There is another red or pink connector plugged into a receptacle on the passenger side of the bracket attached to the header of the frame; no need to disconnect it, because this bracket is not attached to the glass. The rain sensor wiring is threaded through an opening on the glass-mounted bracket.

8. Carefully peel away the rain sensor from the glass surface. You will need a replacement gel pad. Do not turn on the vehicle while the rain sensor is separated from the glass surface.

9. Remove the GPS chip from the windshield bracket and re-install it on the new glass.

10. The top of the windshield has an exposed edge that is close to the top pinchweld wall, which is very susceptible to damage during windshield removal. Before cutout, apply several layers of tape to the pinchweld wall to protect the painted surface.

11. The side moldings are inserted into a retainer riveted to the wall of the pinchweld. To remove, use your fingers to pry them upward.

12. Remove the windshield-wiper nut covers.

13. Remove the windshield-wiper nuts using a 16-millimeter wrench or socket. There are two nuts on the passenger-side wiper. The driver-side wiper is close to the opened hood, but you can still remove the nut while the hood is open.

14. Remove the hood bulb weatherstrip.

15. The cowl panel is inserted in a retainer attached to the bottom edge of the glass. Pry upward using a plastic stick or pry tool. Carefully work the tool from one corner to the other. Note, there are two access panels attached to the cowl panel that you do not need to remove; however, removing them does make removal of the panel easier.

16. There are no gravity stops, nor a place to attach a temporary one. This windshield might require a second person to help set it, or a portable setting tool if a helper is unavailable. Note: Before beginning windshield removal, verify the new windshield is the correct one and the urethanes and primers are current. Never use outdated products as this could jeopardize the structural integrity of the vehicle and the safety of its passengers.

17. Make sure cutting blades are sufficiently sharp. Tape up any areas subject to damage during windshield removal.

18. The interior garnish moldings cannot be removed unless the new air curtain strap is replaced. You can loosen it to get it out of your way, but you cannot remove it completely.

19. Before cutting out the windshield, remove contaminants from the glass and pinchweld to prevent contact with the urethane.

20. Use the cutting tools of your choice to remove the glass from the adhesive bead. If you use a power tool, lubricate the cutting area with water. Spray the top and sides; then make your cuts. The top edge is so close to the pinchweld that damage might be unavoidable. If you have a second technician on hand, use the following procedure: Cut the sides and bottom; then have the second technician pull downward on the glass using vacuum cups, while you cut the top. This might be enough to keep from damaging the paint. It might be necessary to use an aftermarket molding to hide the primed marks.

21. Take the windshield out of the opening using vacuum cups. Make sure the vacuum cups do not overlap a crack in the glass. Lift the glass and place it on a windshield stand or suitable workstation.

22. After cutting the windshield out, remove contaminants such as dirt, moisture and debris from the pinchweld. Clean the dashboard.

23. Dry fit the new glass to the opening. Mark your glass using a grease pencil or retention molding tape.

24. Place your vacuum cups on the new windshield in the appropriate location.

25. Set the windshield onto the old urethane.

26. With the windshield resting in the opening, make sure it is in the right spot.

27. Adjust both sides to the correct setting, marking the passenger side, then the driver side. Lift the glass and place it on a windshield stand or suitable workstation.

28. Follow the urethane manufacturer's recommendations for installation.

29. Clean the inside of the windshield using a urethane manufacturer-recommended product. Do not touch the bonding area of the windshield after cleaning, prepping or priming it.

30. Wear powder-free Nitrile gloves to protect against harsh chemicals.

31. Apply the glass prep and primer following the urethane manufacturer's recommendations.

32. Using the tool of your choice, remove the original urethane bead, leaving 1-2 mm of urethane on the pinchweld. Make sure there are no contaminants and do not touch the pinchweld after prepping the area.

33. Apply the pinchweld primer only to the areas where needed, and follow the urethane manufacturer's recommendations. Allow preps and primers to dry as recommended by the urethane manufacturer.

34. Apply a triangular bead of urethane to the same path as the freshly cut urethane on the pinchweld. Before cutting your V-notch, cut the tip off of your nozzle with a nozzle-cutter. With the cut nozzle, measure to the top of the roofline, and at 1/16-inch higher than the roofline, make a mark on the nozzle with a pen or marker. Notch the nozzle up to the marked line; this will give you the appropriate triangular bead.

35. Lift the windshield from the windshield stand or workstation using vacuum cups. Set the windshield on the urethane at the mark you made during your dry fit. Lower the driver's side of the windshield onto the urethane and line it up with the dry-fit mark; it is now in place.

36. The windshield is now ready to be decked. Press firmly to ensure a good seal.

37. Before re-installing the parts, check for leaks. Use a leak detector to go over the perimeter of the windshield. If you find a leak, apply more pressure or add more urethane to the spot and ensure that the glass makes contact with the wet urethane.

38. Re-install the removed parts in reverse order.

39. Allow the urethane to cure according to the urethane manufacturer's recommended cure time before returning the vehicle to the customer. Warning: Disregarding the safe drive-away time that your urethane manufacturer recommends could jeopardize the structural integrity of the vehicle and the safety of its passengers.

40. You have completed the removal and replacement of the windshield.
By Bob Beranek

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