Tesla Model 3: Windshield (Remove and Replace)

Windshield (Remove and Replace) - Remove

Remove

1. Remove the cowl screen panel. See Panel - Cowl Screen (Remove and Replace).

2. Disconnect the electrical harness from the windshield heater connector.
3. Partially close the hood.

Caution:

Use care not to damage the dashboard.

4. Place a fender cover across the dashboard to protect the dashboard.
5. Remove the headliner. See Headliner (Remove and Install).
6. Remove the forward facing camera. See Camera - Forward Facing (Remove and Replace).
7. Remove the GPS antenna. See Antenna - GPS (Remove and Replace).
8. Remove the relative humidity and temperature sensor. See Sensor - Relative Humidity and Temperature (Remove and Replace).
9. Remove the screw that attaches the windshield electrical harness to the windshield bracket.
10. Remove both the LH and RH lower A-pillar trim. See Trim - A-Pillar - Lower - LH (Remove and Replace).

11. Release the clips that attach the windshield electrical harness to the RH A-pillar area.

12. Disconnect the 3 windshield electrical harness connectors from the RH vehicle harness, and pull windshield electrical harness up through the opening on the RH side of the instrument panel.
13. Tape the windshield electrical harness to the inside of the windshield assembly.
14. Release the clips that attach the windshield electrical harness to the fastener track, and then remove the electrical harness and fastener track from the windshield.
15. Apply masking tape to the exterior of the LH and RH A-pillars to protect the paint from damage.
16. Cut a suitable length of square wire to use with T-handles.
17. Secure the wire to the starter tool and push the tool through the urethane at the RH lower side of the windshield assembly.
18. Remove the wire from the starter tool and remove the tool from the urethane.
19. Secure each end of the wire with a T-handle.
20. With an assistant, use the T-handles to cut the urethane that attaches the windshield assembly to the body.

Caution:

Use care when cutting the urethane at the upper corners and around the VIN plate.

21. Attach suction cups to the LH and RH sides of the windshield assembly.

22. With an assistant, remove the windshield assembly from the vehicle.
23. Remove the suction cups from the windshield assembly.
24. Use a razor blade to remove the old urethane from the windshield flange on the vehicle.

Windshield (Remove and Replace)- Install

Install

Note: Use soft materials to protect the windshield and to prevent scratching.

1. Place the new windshield on a support stand with the windshield bracket facing up.
2. Install the GPS antenna into the windshield bracket, and then install the screw that attaches the antenna to the bracket. Torque 1 Nm

3. Install the relative humidity and temperature sensor into the windshield bracket, and then install the screws that attach the sensor to the bracket.   Torque 1 Nm

4. Install the windshield electrical harness to the windshield bracket, and then install the screw that attaches the harness to the bracket. Torque 1 Nm

5. Connect the windshield electrical harness to the GPS antenna connector.

6. Connect the windshield electrical harness to the humidity and temperature sensor connector.

7. Install the forward facing camera into the windshield bracket, and then connect the windshield electrical harness to the forward facing camera connectors.

8. Install the mount plate onto the windshield bracket, and then install the screws that attach the mount plate to the bracket. Torque 1 Nm

9. Install the glare shield to the windshield bracket, and then install the screws that attach the glare shield to the bracket Torque 1 Nm
10. Bring the mirror front cover to the windshield bracket, and then connect the windshield electrical harness to the occupant camera

11. Install the mirror front cover to the windshield bracket, and then fasten the clips that attach the cover to the bracket.

Note: Make sure that the connector for the rear view mirror passes through the opening in the mirror front cover.

12. Install the fastener track to the windshield electrical harness and windshield, and then fasten the clips that attach the fastener track to the windshield.
13. Tape the end of the windshield electrical harness to the inside of the windshield assembly.
14. Attach suction cups to the LH and RH sides of the windshield assembly.
15. With an assistant, position the windshield assembly onto the vehicle for a dry fit and note any locations where the pads need to be adjusted.
16. If necessary, perform the pad adjustment.

1. Cut Teflon tape into rectangles having dimensions 5mm x 20mm.
2. With an assistant, remove the windshield assembly and set it on a stand.
3. Apply the Teflon tape rectangles to the pads where adjustment is needed.

Note: Make sure that the edges of the tape rectangles align with the edges of the pads.

4. With an assistant, position the windshield assembly onto the vehicle and check the pads fitment.
5. Repeat step 16.a through step 16.d to adjust the pads.

17. With an assistant, remove the windshield assembly and set it back on the stand.
18. Clean the urethane path on the vehicle with an isopropyl alcohol (IPA) wipe. Allow the surface to dry before continuing to the next step.
19. Apply urethane primer to the vehicle body along the urethane path and in areas that were damaged during removal of the windshield assembly.

Note: Allow the primer to dry for at least 1 minute.

20. Apply urethane to the body following the original path.

Note: Make sure that the urethane bead has a triangular cross-section of approximate width 8 mm and height 13 mm.

21. With an assistant, install the new windshield assembly onto the vehicle, but do not set it yet.
22. Align the datums at the top of the windshield assembly.
23. Check the gap and flush of the windshield assembly to the body before fully seating the windshield assembly.
24. Fully seat the windshield assembly, check the gap and flush, and adjust if necessary.
25. Apply masking tape to attach the windshield assembly to the body while the urethane cures.
26. Remove the suction cups from the windshield assembly.
27. Remove the tape from the windshield electrical harness, and move the end of the harness through the opening on the RH side of the instrument panel.

28. Connect the windshield electrical harness to the RH vehicle harness connectors.

29. Secure the windshield harness clips to the RH A-pillar area.
30. Install both the LH and RH lower A-pillar trim. See Trim - A-Pillar - Lower - LH (Remove and Replace).
31. Install the headliner. See Headliner (Remove and Install).

32. Connect the electrical harness to the windshield heater connector.
33. Install the cowl screen panel. See Panel - Cowl Screen (Remove and Replace).
34. Perform the forward facing camera target calibration. See Camera - Forward Facing (Target Calibration).
35. Remove the masking tape after the urethane has cured.

Caution:

Do not drive the vehicle until the adhesive manufacturer's recommended minimum drive-away time has passed. Dow Betaseal Express has a drive-away time of 1 hour minimum in temperatures of 0˚F (-18˚C) or warmer. If using an equivalent product, refer to the adhesive packaging for the safe drive-away time. If necessary, leave the tape applying pressure to the glass on the vehicle and advise the customer that they can remove it after 24 hours. Additionally, advise the customer that they should avoid high driving speeds and speed bumps for the next 24 hours.