Removal and Replacement

WINDSHIELD GLASS

Special Tool(s)

Special Tool(s):

Material

Material:

Removal
1. Remove the RH and LH side A-pillar trim panels, sun visors, retainers and, if equipped, overhead console.
2. Remove the interior rear view mirror.
3. Partially lower the front portion of the headliner near the windshield upper opening and block with suitable material.
4. Remove the cowl panel grille.

5. NOTE: LH side shown, RH side similar.

Press and hold the inside edge of the roof ditch moulding away from the centerline of the vehicle.







6. NOTE: LH side shown, RH side similar.

Carefully twist the outside edge of the roof ditch moulding upward to release it from the outside edge of the Y-clip.







7. NOTE: LH side shown, RH side similar.

Push the outside edge of the moulding in toward the center of the vehicle and slide the moulding off the inside edge of the Y-clip.







8. Release the moulding from the remaining 3 Y-clips and remove the moulding.

9. NOTE: LH side shown, RH side similar.

Remove the Y-clips.
- Starting with the bottom Y-clip, work upward toward the roof. Use light pressure to separate the A-pillar track near the Y-clip, then remove the Y-clip.







10. Before cutting the urethane adhesive, remove dirt and other foreign material from the windshield pinchweld area.
- Use a clean shop towel or oil-free compressed air.

11. NOTE: Refer to the manufacturer's instructions before using the special tool.

Lubricate the urethane adhesive with water to aid the Interior Auto Glass Cut-Out Knife Kit when cutting the urethane adhesive.

12. WARNING:
- Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury.
- Wear protective gloves when handling components or parts that have pointed or sharp edges. Failure to follow this instruction may result in serious personal injury.

CAUTION: To avoid rust formation, use extreme care not to scratch the paint or primer or otherwise damage the pinchweld during glass removal.

NOTE:
- Insert the blade into the special tool so that the flat side is against the glass. This will leave the entire urethane adhesive bead on the pinchweld and allow a dry fit of the replacement windshield glass.
- Support the windshield glass to prevent the glass from dropping while cutting the urethane adhesive.

Insert the special tool at the upper center of the windshield glass and work toward the bottom corners.







13. Using the special tool, distance the windshield from the body.







14. NOTE: Removing the windshield glass requires more than one technician.

Using the special tool, cut the remaining urethane adhesive and remove the window glass and place on a stable work surface.







Installation
1. Inspect the glass spacer blocks for damage. If necessary, install new spacer blocks.
2. Dry-fit the windshield glass on the existing urethane adhesive bead on the pinch weld.
- Position the windshield glass on the pinch weld.
- Center the glass in the opening.
- Adjust the windshield spacer blocks as needed for best fit.
- Make alignment marks with tape or non-staining grease pencil (preferably at the spacer blocks) on the windshield glass and the body.

3. After the dry-fit alignment, remove the glass from the body opening and place on a stable work surface with the interior side of the glass facing upward.

4. WARNING: Repair any corrosion found on the pinch weld. The pinch weld is a structural component of the vehicle. Corrosion left unrepaired may reduce the structural integrity of the vehicle. Failure to follow this instruction may result in serious injury to vehicle occupant(s).

NOTE: Avoid scratching the pinch weld. For minor scratches or exposed metal on the pinch weld, see the manufacturer's recommendations.

Using an appropriate tool, trim the urethane adhesive leaving a 1-2 mm (0.04-0.08 in) base of original equipment urethane on the pinchweld.







5. Using a clean shop towel, brush or oil-free compressed air, clean the pinch weld area around the existing urethane. Remove any foreign material or water that may have entered during glass removal.
6. If reinstalling the same windshield glass, remove the remaining urethane adhesive from the glass leaving a thin layer to bond with the new urethane bead.
7. Clean the inside of the windshield glass surface with glass cleaner.
- Make sure to thoroughly clean the surface of the blackened border area where the urethane adhesive will be applied.

8. CAUTION: Be sure to use the same brand and cure-rate products for the adhesive and primer. Do not mix different brands of urethane and primer. Refer to the Material Chart in this procedure.

NOTE: Sika uses the same black primer for the glass and pinch weld area.

If installing a new windshield glass, apply urethane glass primer according to manufacturer's instructions. Allow at least 6 minutes to dry.

9. Cut the urethane applicator tip to specification.







10. NOTE:
- Use either a high-ratio, electric or battery-operated caulk gun that will apply the urethane with less effort and continuous bead.
- The windshield glass must be positioned within 10 minutes of applying the urethane adhesive.

Apply a uniform bead of urethane adhesive on top of the existing trimmed urethane adhesive bead on the pinch weld.
- Make sure that all gaps in the urethane adhesive are smoothed into one continuous bead starting and ending at the bottom of the windshield glass near the center.







11. WARNING: Do not drive vehicle until the urethane seal has cured. Follow urethane manufacturer's curing directions. Inadequate or incorrect curing of the urethane seal will adversely affect glass retention. Failure to follow these instructions may result in serious injury to vehicle occupant(s).

CAUTION: Before positioning the windshield glass, open vehicle windows to prevent the air pressure of closing doors from affecting the adhesive bond.

Using the alignment marks made previously, position the windshield glass on the pinch weld.

12. NOTE: The urethane adhesive must cure for a minimum of one hour before testing for air or water leaks.

After the urethane has cured, check the windshield glass seal for air or water leaks through the urethane adhesive bead and add urethane adhesive as necessary.

13. Install the Y-clips.
- Each Y-clip snaps into a slot on the bottom of the roof ditch moulding.







14. Install the roof ditch mouldings.
15. Install the cowl panel grille.
16. Raise the front portion of the headliner near the windshield upper opening and install.
17. Install the interior rear view mirror.
18. Install the RH and LH side A-pillar trim panels, sun visors, retainers and, if equipped, overhead console.