Land Rover Defender: Alpine Window

REMOVAL AND INSTALLATION

SPECIAL TOOL(S)

JLR-501-176

Fiber-lined Glass Removal Tool Kit

REMOVAL

CAUTIONS:

• Place the glass on felt covered supports with the locating studs facing up. Do not stand on edge as this can cause chips which subsequently develop into cracks.
• Protect the surrounding paintwork to avoid damage.

NOTES:

• This procedure contains some variation in the illustrations depending on the vehicle specification, but the essential information is always correct.
• This procedure contains illustrations showing certain components removed to provide extra clarity.
• This component is available in multiple variations. Before the alpine window is removed, check the part numbers for a correct application.

1. Disconnect the startup battery ground cable.

2. Remove the headliner.

3. Remove the roof panel mouldings.

4.

• Remove the 5 screws.
• Remove the alpine window interior trim.

5.

• The illustration is used to index the contents of the fiber-lined glass removal special tool.
• Make sure that the contents of the fiber-lined glass removal special tool kit are complete and no items are damaged or missing.
• Consult the instruction manual supplied with the fiber-lined glass removal special tool before commencing the removal of the alpine window.
• (A) Instrument Panel protector
• (B) Cutting fiber threading tool
• (C) Pick
• (D) Spider cutting tool
• (E) Anchor suction tool
• (F) Cutting fiber install tool
• (G) Cutting fiber

6.

• Use the necessary items from the special tool JLR-501-176 fiber-lined glass removal tool kit to release the seal and remove the alpine window.

  Special Tool(s): JLR-501-176

7.

Use suitable tools and remove all residual sealant from the body.

INSTALLATION

1.

Install the 4 spacers to the body as illustrated.

2.

Follow the instructions included with the Jaguar Land Rover PU adhesive sealant kit and apply sealant to the areas illustrated. Make sure to use Polyurethane SIKA JLR-5, or if not available use an equivalent JLR approved PU adhesive kit.

3.

CAUTIONS:

• Make sure that the PU adhesive only touches the body at the designated areas. New PU adhesive sealant needs to be applied to the alpine window if the PU adhesive sealant is accidentally disturbed.
• Make sure that the mating faces are clean and free of foreign material.
• Make sure that no excess sealant residue is evident.
• Make sure to apply even pressure along the edges of the alpine window.

NOTE: This step requires the aid of another technician.

With assistance, install the alpine window in the sequence illustrated. An audible click is heard when a clip is properly installed.

4.

Check if the gaps around the edges of the alpine window are even.

5.

CAUTIONS:

• Wait at least 2 hours to allow the PU adhesive to dry before applying water to the alpine window.
• Do not use high pressure water equipment to complete this step.

• Apply water around the alpine window at the areas illustrated. Mark any area that shows water ingress.
• If the check fails and water ingress is evident, remove the alpine window and repeat the installation procedure. Do not attempt to apply additional sealant to areas that show water ingress.

6. Install the roof panel mouldings.

7. Install the headliner.

8. Connect the startup battery ground cable.

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