Training Time March/April 2022

2007 Porsche Cayman Replacement

By Alfredo Calva

1 This sporty car has quite a difficult windshield replacement. It’s very technical, and many parts have to be removed. I still remember the first one I replaced because it took me a few hours to complete.

2 Start by doing a detailed pre-inspection to avoid missing anything. Test the rain sensor as part of your pre-inspection to ensure it’s working properly. After, start removing the cowling, and remove the end plastic covers by gently pulling them off.

3 After removing the covers, remove a 10 mm nut, then remove the brackets underneath. Be sure to note the direction in which they are positioned since they are different and the driver’s side has a different setup.

4 Twist the plastic screws one-quarter of a turn and pull up to release them. Pull the cover towards the front of the vehicle and lift it up simultaneously to release the hook tabs in the front. Next, remove the left and right covers the same way.

5 To remove the wipers, you’ll need a thin 13 mm socket with a small ratchet. After removing the nut, close the hood, lift the wiper arm, and rock it side-to-side with one hand. With the other hand, grab the bottom to protect the hood.

6 Remove the torx 25 screw after removing the passenger side wiper arm.

7 It’s time to go back under the hood to remove more parts. Two clips are
located in the bottom center of the cowling. Be careful not to drop them.

8 Unplug the two wire connectors and disconnect the windshield wiper fluid hose.

9 To remove the cowling, it’s best to close the hood half-way down for easier removal.

10 I highly recommend placing all the parts on a table, in the order removed.

11 To remove the rearview mirror cover , separate it from the middle  with your tool of choice. If the top is too tight, try the bottom.

12 To remove the rearview mirror, grab it with two hands and wiggle it down. Be careful not to pull down too hard as there are cables connected.

13 Separate the neck cover, so you can dismount the rain sensor.

14 To remove the rain sensor, slowly ply away from the bracket.

15 To unplug the antenna, the passenger side A-pillar cover must be removed. I start by plying off the center top to release the clips.

16 Remove the end by plying away the quarter panel cover and taking it off. There are three clips, so start at the top and work your way down.

17 Once all the clips have been unclipped from the end, as well as the ones near the windshield, bring the seat down. Pull down on the quarter panel cover to finish removing the A-pillar cover. Next, slide the whole cover towards the back of the vehicle as it has to unhook off the dash. Now you’ll have access to unplug the antenna.

18 It is time to start removing the windshield. Removing the moulding is optional since there’s enough space to fit the fiber line or wire if you decide on that method to cut out the glass. If you choose to remove the moulding to gain more space, pull it off with needle-nose pliers.

19 Prep the glass and the pinchweld accordingly to your adhesive manufacturer’s recommendations. Before you set the glass, be sure to remove the double-sided tape orange protective strip.

20 When you set the glass, you have to be super precise since the double-sided tape will adhere to the body and make it difficult to reposition the glass. I use a two-man set on this vehicle. After decking the glass, I pull the moulding with my fingers all the way around to mold it just how it was before.

21 To secure the bond of the double-sided tape to the body, the best way to hold it down is by using blue tape.

22 This is the goal. Notice how the moulding sits nicely flush to the body, just as it did before.

23 Reinstall everything in reverse order of removal. When reinstalling the cowling, remember to lower the hood halfway down for easier fitting. When reinstalling the rain sensor, I prefer applying rain sensor gel rather than using a pad since there is a higher chance of ending up with a bubble. Also, be sure to remove all the metal clips off the vehicle from the A-pillar cover. They normally end up in the body rather than the cover, and they need to be in the cover to reinstall back on.

24 This vehicle is ready to get back on the road safely. This is definitely a challenging installation, but that’s what makes our trade fun and interesting. We get to work on so many different vehicles, and all we need is patience and attention to detail to accomplish a safe, quality job.

Alfredo Calva is the president of Alfredo’s Auto Glass in Corona, Calif.

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