Windshield: Service and Repair
WINDSHIELD GLASSSpecial Tool(s)
Special Tool(s):
Material
Material:
Removal
1. Remove the windshield wiper pivot arms.
2. Remove the A-pillar trim panel.
3. Remove the sun visors.
4. Remove the sun visor clips.
5. Lower the front portion of the headliner.
6. Remove the interior rear view mirror.
7. Using a soft brush or vacuum, remove any dirt or foreign material from the pinch weld area.
8. NOTE: Refer to manufacturer's instructions before using the tool.
Lubricate the urethane adhesive with water to aid the Interior Auto Glass Cut-Out Knife Kit when cutting the urethane adhesive.
9. 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 pinch weld 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 pinch weld and allow a dry fit of the replacement windshield glass.
- Support the windshield glass as necessary 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.
10. Using the special tool, distance the windshield glass from the body.
11. Using the special tool, cut the remaining urethane adhesive and carefully remove the windshield glass and place on a stable work surface.
Installation
1. Dry fit the windshield glass on the existing urethane bead on the pinch weld.
- Position the windshield glass on the pinch weld.
- Center the windshield glass in the opening.
- Adjust the windshield glass stop blocks (if equipped) as needed for best fit.
- Make alignment marks with tape or non-staining grease pencil (preferably at the windshield glass stop blocks, if equipped) on the windshield glass and the body.
2. After the dry-fit alignment, remove the glass from the windshield opening and place on a stable work surface with the interior side of the glass facing up.
3. 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 windshield removal.
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 pinch weld.
5. 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.
6. Clean the inside of the glass surface with glass cleaner.
7. NOTE:
- 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.
- 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.
8. Cut the urethane applicator tip to specification.
9. NOTE: Use either a high-ratio, electric or battery-operated caulk gun that will apply the urethane with less effort and a continuous bead.
Apply 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 near the center.
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 window to prevent the air pressure of closing doors from affecting the adhesive bond.
10. Position the windshield glass, aligning the marks made previously.
11. NOTE: The urethane adhesive must cure for a minimum of one hour before testing for air or water leaks.
Check the installation for air and water leaks through the urethane bond and add urethane adhesive where needed.
12. Install the A-pillar trim panel.
13. Install the inside rear view mirror.
14. Install the sun visor clips.
15. Install the sun visors.
16. Install the windshield wiper pivot arms.