Pre-Installation Glass Inspection

This procedure explains how to inspect new windshield, roof, door, and fixed glass components before the new component is installed.

New glass components (windshield, roof, door, and fixed glass) must be inspected before installation. If the new component has manufacturing defects or has been damaged during transit, repair may be possible, depending on the type and amount of damage. If the damage or defect is too severe, the new glass component must be scrapped (destroyed), and a replacement component is obtained through the warranty or RMA process.

The criteria to determine if a new glass component is repairable or if the component must be scrapped are based on the type, severity, and location of the damage. Use the images and information below to determine if the glass component may be repaired or if replacement is required.

Inspection Procedure

For each new glass component, perform a visual inspection for scratches. If a scratch is noted, perform a tactile inspection on the defect to determine if the component can be repaired.

Table 1. Inspection Method
Inspection Type Notes
Visual:
  • Lighting:
    Perform the inspection in a well lighted area. During the inspection, lighting should be any of the following (in order of preference):
    1. Overhead lighting in the range of 1200–3500 lux (lx).
    2. Sunlight.
    3. Normal overhead or room lighting.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not use a flashlight or portable light source when performing the inspection.
  • Viewing Criteria:
    • View from a distance of approximately 1 meter.
    • View the glass at an angle between 75–115 degrees.
    • Typically, the inspection should take 5–15 seconds per glass component.
If scratches are visible, note the number and location of each scratch, and if there is discoloration caused by the scratch, then perform a tactile inspection of each scratch.
Tactile:

Pressing lightly down, move your fingernail across the scratch (not along the length of the scratch). Repeat the test every 2–3 mm along the length of the scratch.

If you feel the scratch, note which scratch(es) can be felt.

Once the inspection is complete, refer to the Door and Roof Glass Inspection Criteria for information about if the glass should be installed as-is, repaired, or if a new component is required.

Windshield Inspection Criteria

Visually inspect each windshield zone:

Table 2. Windshield Glass Inspection Zones

LHD vehicles

RHD vehicles
Informational PurposesAn informational icon, calling your attention
Note
If any of the criteria are exceeded, the component must be replaced.
Table 3. Windshield Glass Inspection Criteria and Allowed Repairs
Windshield Zone Layer Defect/Issue Install, Repair, or Replace
A: Camera Field of View (FOV) Interior or exterior surface layers of the windshield Bubbles, digs, pits, adhesions, chips, or foreign object inclusions up to 0.5 mm.
  • Up to 5: Install the component as-is.
  • 6 or more: Replace the component.
Bubbles, digs, pits, adhesions, chips, or foreign object inclusions larger than 0.5 mm. Replace the component.
Light scratch (cannot be felt with fingernail, and without discoloration) up to 4 mm. in length.
  • Up to 2: Repair the component (see Remove Scratches).
  • 3 or more: Replace the component.
Medium scratch (can be felt with fingernail, without discoloration) or deep scratch (can be felt with fingernail, with discoloration). Replace the component.
Laminate layer Foreign object inclusions up to 0.5 mm.
  • Up to 5: Install the component as-is.
  • 6 or more: Replace the component.
Foreign object inclusions larger than 0.5 mm. Replace the component.
Bubbles, wrinkles, digs, pits, adhesions, chips, PVB shrinkage, or PVB excess. Replace the component.
B: General viewing area Interior or exterior surface layers of the windshield Bubbles, digs, pits, adhesions, chips, or foreign object inclusions up to 0.8 mm.
  • Up to 3, each at least 150 mm apart: Install the component as-is.
  • 2 or more separated by less than 150 mm: Replace the component.
  • 4 or more: Replace the component.
Bubbles, digs, pits, adhesions, chips, or foreign object inclusions larger than 0.8 mm. Replace the component.
Light scratch (cannot be felt with fingernail, and without discoloration) up to 15 mm. in length.
  • Up to 2, separated by at least 150 mm: Repair the component (see Remove Scratches).
  • 3 or more: Replace the component.
Medium scratch (can be felt with fingernail, without discoloration) more than 15 mm in length.
  • 1: Repair the component (see Remove Scratches).
  • 2 or more: Replace the component.
Deep scratch (can be felt with fingernail, with discoloration). Replace the component.
Laminate layer Foreign object inclusions up to 0.8 mm.
  • Up to 3, each at least 150 mm apart: Install the component as-is.
  • 2 or more separated by less than 150 mm: Replace the component.
  • 4 or more: Replace the component.
Foreign object inclusions larger than 0.8 mm. Replace the component.
Bubbles, wrinkles, digs, pits, adhesions, chips, PVB shrinkage, or PVB excess. Replace the component.
C: Driver's viewing area Interior or exterior surface layers of the windshield Bubbles, digs, pits, adhesions, chips, or foreign object inclusions up to 0.8 mm.
  • 1: Install the component as-is.
  • 2 or more: Replace the component.
Bubbles, digs, pits, adhesions, chips, or foreign object inclusions larger than 0.8 mm. Replace the component.
Light scratch (cannot be felt with fingernail, and without discoloration) up to 15 mm. in length.
  • Up to 2, separated by at least 150 mm: Repair the component (see Remove Scratches).
  • 3 or more: Replace the component.
Medium scratch (can be felt with fingernail, without discoloration) more than 15 mm in length.
  • 1: Repair and the component (see Remove Scratches).
  • 2 or more: Replace the component.
Deep scratch (can be felt with fingernail, with discoloration). Replace the component.
Laminate layer Foreign object inclusions up to 0.8 mm.
  • 1: Install the component as-is.
  • 2 or more: Replace the component.
Foreign object inclusions larger than 0.8 mm. Replace the component.
Bubbles, wrinkles, digs, pits, adhesions, chips, PVB shrinkage, or PVB excess. Replace the component.
D: Windshield border/frit area Interior or exterior surface layers of the windshield Bubbles, digs, pits, adhesions, chips, or foreign object inclusions up to 1 mm.
  • Up to 3, each at least 150 mm apart: Install the component as-is.
  • 2 or more separated by less than 150 mm: Replace the component.
  • 4 or more: Replace the component.
Digs, pits, adhesions, chips, or foreign object inclusions larger than 1 mm. Replace the component.
Light scratch (cannot be felt with fingernail, and without discoloration) up to 30 mm. in length.
  • Up to 2, separated by at least 150 mm: Repair the component (see Remove Scratches).
  • 3 or more: Replace the component.
Medium scratch (can be felt with fingernail, without discoloration) more than 30 mm in length.
  • Up to 2, separated by at least 150 mm: Repair and install the component (see Remove Scratches).
  • 3 or more: Replace the component.
Deep scratch (can be felt with fingernail, with discoloration). Replace the component.
Laminate layer Foreign object inclusions up to 1 mm.
  • Up to 3, each at least 150 mm apart: Install the component as-is.
  • 2 or more separated by less than 150 mm: Replace the component.
  • 4 or more: Replace the component.
Foreign object inclusions larger than 1 mm. Replace the component.
Bubbles up to 1 mm.
  • 1: Install the component as-is.
  • 2 or more: Replace the component.
Wrinkles Replace the component.
PVB shrinkage on glass edge.
  • Up to 1.5 mm: Install the component as-is.
  • More than 1.5 mm: Replace the component.
PVB excess on glass edge.
  • Up to 0.5 mm: Install the component as-is.
  • More than 0.5 mm: Replace the component.

If a component fails the inspection, refer to Report Defects and Obtain a Replacement Component.

Door and Roof Glass Inspection Criteria

When inspecting new door and window glass components, use the following table to determine if the component can be repaired, installed as-is, or if replacement is required.

Informational PurposesAn informational icon, calling your attention
Note
If any of the criteria are exceeded, the component must be replaced.
Table 4. Door and Roof Glass Inspection Criteria and Allowed Repairs
Defect Type Criteria Allowed Repairs
Light scratch Cannot be felt with fingernail, without discoloration:
  • Up to 5 mm in length, and up to 3 allowed within a 300 mm diameter
  • 10 mm, and 1 allowed for whole component
 Repair (refer to the glass repair kit manufacturer's instructions).
Medium scratch Can be felt with fingernail, without discoloration:
  • Up to 1 mm in length:
Repair (refer to the glass repair kit manufacturer's instructions).
Deep scratch Can be felt with fingernail, with discoloration. None; component must be replaced
Internal contamination Any visible inclusion (any material), discoloration, or void (bubble) that is:
  • Length: up to 5 mm
  • Width: up to 1 mm
 None; install the component as-is.
Informational PurposesAn informational icon, calling your attention
Note
If any inclusion, discoloration, or void, is longer than 5 mm or wider than 1 mm, the component must be replaced.
Excess primer Any primer outside the seal. Remove the excess primer (see Remove Excess Primer).
Chip Any number, size, or location None; component must be replaced
Delamination Any None; component must be replaced
Crack Any visible crack None; component must be replaced
For each door and window glass component, visually inspect all edges that will be visible after installation. Inspect for:
  • Broken, chipped, or cracked edges
  • Separation between the laminate (middle) layer of the glass and the interior and/or exterior glass layers

Acceptable: Install accepted components.

Not Acceptable: Replace rejected components.

If a component fails the inspection, refer to Report Defects and Obtain a Replacement Component.

Remove Excess Primer

Excess primer (any visible primer outside the seal area) must be removed before installing the glass component. Instead of rejecting and scrapping the glass component, remove excess primer and install the component if it is otherwise acceptable.

Removing excess primer requires:
  • New razor blade
  • Shop towels
  • Water/alcohol mix
  1. Hold the razor blade at very a shallow angle and lightly scrape to remove the excess primer.
    Informational PurposesAn informational icon, calling your attention
    Note
    Scrape using only light pressure to reduce the chances of scratching the glass. Any light scratches caused by primer removal can be removed (see Remove Scratches).
  2. Wipe the removed primer off the razor blade and scrape again if necessary.
  3. Dampen a shop towel with the water/alcohol mix.
  4. Clean the area with the damp shop towel.
  5. Repeat as necessary, until all the excess primer is removed.

Remove Scratches

Light and medium scratches may be removed by polishing the glass using polishing cream and a buffing wheel.

Warning IconA warning icon, calling your attention to a possibly risky situation
Warning
Glass polishing must be done at low to moderate temperature to avoid causing color distortion or cracks. Water is used between polishing passes of the scratches area.
Removing excess primer requires:
  • Buffing wheel mounted on an electric drill or polisher
  • Polishing cream (rubbing compound)
  • Scratch removal cream
  • Shop towels
To remove light and medium scratches:
Informational PurposesAn informational icon, calling your attention
Note
Deep scratches cannot be repaired. Instead, the component must be replaced.
  1. Clean the area of the scratch using a damp shop towel.
  2. Apply a light coating of polishing cream to the buffing wheel.
  3. Polish the area containing the scratch using light pressure and multiple passes.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Polish the entire repair area and a small area around the repair area to blend the repair into the rest of the glass component.
  4. Clean the repair area with a damp shop towel.
  5. Examine the scratched area to see if the scratch is still present.
  6. Repeat as necessary, until the scratch is removed.

Report Defects and Obtain a Replacement Component

Report defects to help improve quality and to begin the component replacement process.

  • Tesla Service Centers or Tesla Collision Centers:
    1. Circle each defect using a paint pen or a grease pen.
    2. Take a photo that clearly shows each defect.

    3. Take a photo that shows the entire glass component, with all defects circles.

    4. Use the Tesla Service Center App to upload the photos.
      Informational PurposesAn informational icon, calling your attention
      Note
      Make sure to choose the correct symptom.
    5. Provide component manufacturing information:

  • Tesla Approved Collision Centers or Tesla Approved Body Shops:
    1. Follow the RMA return procedure.