Windshield: Service and Repair
Windshield Removal and Installation
Removal
1. Both Windshield Wiper Arm Assemblies
NOTE: Set the wiper arms to the auto-stop position before removal.
1. Remove the caps (A) and nuts (B).
2. Remove the wiper arms (C).
2. Front Fender Trim - Both Sides
NOTE: Repeat on the opposite side.
1. Remove the clips (A, B).
2. Pull up the front fender trim (C) by hand to detach the clips (D), then remove the trim.
3. Cowl Top Cover - Both Sides
NOTE: Repeat this procedure on the opposite side.
1. Remove the clip (A).
2. Pull out the hood rear seal (B).
3. Detach the hooks, and remove the cowl top cover (C).
4. Side Cowl Cover - Both Sides
NOTE: Repeat on the opposite side.
1. Detach the hook (A) at the inside of the cowl cover (B).
2. Release the hooks (C) from the cowl cover and the front fender (D), then remove the side cowl cover (E).
3. Right side; Detach the windshield washer tube.
5. Center Cowl Cover
1. Remove the clips (A).
2. Carefully pull the center cowl cover (B) forward to release the hooks (C) from the windshield and the body.
6. Front Door Opening Seal As Needed - Both Sides
1. Pull out the front door opening seal (A) from the trim hooks (B) around the front door opening flange, then detach the seal as needed.
2. Repeat this step on the opposite side.
7. A-Pillar Trim - Both Sides
NOTE: Repeat on the opposite side.
1. Pull out the A-pillar trim (A) by hand to release the clips (B, C).
2. Put a shop towel (A) in the opening between the A-pillar trim (B) and the dashboard to prevent dropping the A-pillar clips.
3. Pull out and up on the A-pillar trim (A) to release it from the dashboard.
NOTE: The upper clip will stay in the body.
4. Remove the upper clip (A) from the body.
8. Rearview Mirror
Without auto diming mirror
1. Using a plastic trim tool, press down on the tab, slide the mirror base (A) rearward, then remove the rearview mirror.
With auto diming mirror
1. Carefully pry out the rearview mirror harness cover (A) to release the hooks (B), then slide the cover rearward.
2. Release the rearview mirror harness cover from the hooks (C) of the rearview mirror harness cover base (D).
3. Disconnect the rearview mirror connector (A).
4. Loosen the screw (A) with a TORX T20 bit, then slide the rearview mirror (B) rearward and off the mount (C).
9. Sunvisor - Both Sides
NOTE: Repeat on the opposite side.
1. Push the tab (A) with a flat-tip screwdriver through the hole in the front side of the bracket cover (B).
NOTE: Make sure the tab is unlocked.
2. While pushing in the tab (A) with a flat-tip screwdriver, release the sunvisor (B) from the holder (C), and rotate the sunvisor backward 45 °.
NOTE: Make sure the tab slides into the bracket cover as you rotate the sunvisor.
3. Disconnect the connector (A), then remove the sunvisor (B).
NOTE: If the sunvisor cannot be removed, the tab has not rotated into the bracket cover. Repeat step 2 to rotate the tab.
10. Roof Console Assembly
1. Remove the lenses (A), then remove the screws (B).
2. Open the console, then remove the screws (C).
3. Disconnect the connectors (D), then remove the roof console assembly (E).
11. Headliner As Needed - Front Side
1. Detach the front area of the headliner (A) as needed.
12. Roof Molding - Both Sides
NOTE: Repeat on the opposite side.
1. Carefully insert the large trim tool (A) under the molding next to the lower clip (B).
2. While pulling up the clip area of the molding by hand, push each of the six small hooks (C) to release the clip from the retainer (D) on the A-pillar. Do not pry up the clip if it is hard to release it from the clip on the A-pillar.
3. Gradually work your way up to release each of the upper clips (E, F, G).
4. Start from the front to the rear, carefully insert a trim tool in under the roof molding (A) next to each of the retainers (B, C). Slide and pry up the retainers to release it with the clips from the stud bolts (D) and the pins (E) on the body.
5. Slide the rear end of the roof molding (A) forward to release it from the body, then remove the roof molding from the body.
6. Pry up the middle hooks (A) with a flat-tip screw driver to release the retainer (B) from the roof molding (C).
13. Roof Rail - Both Sides
NOTE: Repeat on the opposite side.
1. Remove the caps (A). (4 Places)
2. Remove the roof rail (A).
14. Side Windshield Trim - Both Sides
NOTE: Repeat on the opposite side.
1. Carefully insert the large trim tool (A) under the trim next to the lower clip (B).
2. While pulling up the clip area of the trim by hand, push each of the six small hooks (C) to release the clip from the retainer (D) on the A-pillar. Do not pry up the clip if it is hard to release it from the clip on the A-pillar.
3. Gradually work your way up to release each of the upper clips (E, F, G).
15. Windshield
1. Remove the windshield molding (A) from the upper edge of the windshield (B). If necessary, cut the windshield molding with a utility knife.
2. If the original windshield will be reinstalled, make alignment marks (A) across the glass and the body with a grease pencil.
3. Apply protective tape along the edge of the dashboard and the body. Make a hole with an awl through the rubber dam, the adhesive, and the dashboard seal from inside of the vehicle at a corner portion of the windshield. Push a piece of piano wire through the hole, and wrap each end around a piece of wood.
Cutting positions
4. With a helper on the outside, pull the piano wire (A) back and forth in a sawing motion. Hold the piano wire as close to the windshield (B) as possible to prevent damage to the body and the dashboard. Carefully cut through the rubber dam and the adhesive (C) around the entire windshield.
5. Carefully remove the windshield.
Installation
1. Windshield
1. Scrape smooth the original adhesive with a knife until there is a thickness of about 2 mm (0.08 in) on the bonding surface around the entire windshield opening flange:
* Do not scrape down to the painted surface of the body; damaged paint will interfere with proper bonding.
* Remove the rubber dam and the fasteners from the body.
2. Clean the body bonding surface with a shop towel dampened in isopropyl alcohol. After cleaning, keep oil, grease, and water from getting on the clean surface.
3. If you are reinstalling the original windshield, scrape off all of the original adhesive, the clips, the dashboard seal, and the rubber dam from the windshield with a putty knife. Clean the boning surface on the inside face and the edge of the windshield with isopropyl alcohol. Make sure the bonding surface is kept free of water, oil, and grease.
4. Apply glass primer to the upper clip mounting areas on the windshield (A), and let it dry. Remove the adhesive backing, and attach the side rubber dam (B) and the upper clips (C) to the inside face of the windshield as shown:
* Be sure the rubber dams and the clips line up with the alignment marks (D, E, F).
* Be careful not to touch the windshield where the adhesive will be applied.
5. Attach the dashboard seal (A) with adhesive tape to the inside surface of the windshield (B) as shown, using the edge of the black ceramic-coated area (C) as shown:
* Make sure the dashboard seal lines up with the alignment marks (D).
* Be careful not to touch the windshield where the adhesive will be applied.
6. Attach the windshield molding (A) with adhesive tape (B) to the upper edge of the windshield (C).
NOTE: Be careful not to touch the windshield where the adhesive will be applied.
7. Set the windshield (A) in the opening, and center it. Make alignment marks (B) across the windshield and the body with a grease pencil at the four points shown:
* Make sure both clips (C) contact with the edge of the body holes.
* Be careful not to touch the windshield where the adhesive will be applied.
8. Remove the windshield.
9. Apply a light coat of glass primer along the edge of the windshield (A) between the rubber dam (B) and the windshield moldings (C) as shown, then lightly wipe it off with gauze or cheesecloth:
* Apply the glass primer to around edge of the windshield using the printed dots (D) on the windshield as a guide.
* Do not apply body primer to the windshield, and do not mix up the body primer applicator and the glass primer applicator.
* Never touch the primed surfaces with your hands. If you do, the adhesive may not bond to the windshield properly, causing a leak after the windshield is installed.
* Keep water, dust, and abrasive materials away from primed surfaces.
10. Carefully apply a light coat of the body primer to any exposed paint or metal on the windshield mounting flange. Let the body primer dry for at least 10 minutes:
* Do not apply the glass primer to any remaining original adhesive on the flange.
* Cover on the dashboard before applying the body primer.
* Do not to mix up the body primer applicator and the glass primer applicator.
* Never touch the primed surfaces with your hands.
11. Cut a "V" in the end of the nozzle (A) on the adhesive cartridge as shown.
12. Put the cartridge in a caulking gun, and run a continuous bead of the adhesive (A) around the edge of the windshield (B) along the edge of the rubber dam (C) and the windshield moldings (D) as shown:
* Use the printed dots (E) as a guide when you apply the adhesive to the windshield.
* Apply the adhesive within 30 minutes after applying the glass primer.
* Make a slightly thicker bead at each corner.
13. Hold the windshield with suction cups over the opening, align it with the alignment marks and set it down on the adhesive. Lightly push on the windshield until its edges are fully seated on the adhesive all the way around.
NOTE: Do not open or close any of the doors for about an hour until the adhesive is dry.
14. Remove the excess adhesive with a putty knife or a shop towel dampened with isopropyl alcohol.
15. Wait at least an hour for the adhesive to dry, then spray water over the windshield and check for leaks. Mark the leaking areas, let the windshield dry, then seal with sealant: Let the vehicle stand for at least 4 hours after windshield installation. If the vehicle has to be used within the first 4 hours, it must be driven slowly.
16. Advise the customer not to do the following things for 2 to 3 days:
* Slam the doors with all the windows rolled up.
* Twist the body excessively (such as when going in and out of driveways at an angle or driving over rough, uneven roads).
2. Side Windshield Trim - Both Sides
NOTE: Repeat this procedure on the opposite side.
1. Install the side windshield trim (A).
3. Roof Rail - Both Sides
NOTE: Repeat on the opposite side.
1. Install the roof rail (A), then install the nuts (B).
2. Install the caps (A). (4 Places)
4. Roof Molding - Both Sides
NOTE: Repeat on the opposite side.
1. Install the retainers (A) to the pins (B) on the body. (4 places)
2. Slide the rear end of the roof molding (A) rearward to install it to the body.
3. Push on the clip areas (A) of the roof molding (B) until the clips lock into the retainers (C) securely, and the retainer (D) into the stud bolts (E).
4. Make sure the roof molding is installed securely.
5. Headliner As Needed - Front Side
1. Install the headliner (A).
6. Roof Console Assembly
1. Connect the connectors (A), then install the roof console assembly (B).
2. Install the screws (C, D), then install the lenses (E).
7. Sunvisor - Both Sides
NOTE: Repeat on the opposite side.
1. Connect the connector (A), and install the sunvisor (B).
2. While holding the bracket cover (A), rotate the sunvisor (B) forward until the tab (C) snaps into place.
3. Gently pull down on the sunvisor to make sure it is properly secured in the body.
4. Rotate the sunvisor into the holder (D).
8. Rearview Mirror
Without auto diming mirror
1. Fit the mirror base (A) over the mount (B), and secure the rearview mirror.
With auto diming mirror
1. Slide the rearview mirror (A) forward to the mount (B), then tighten the screw (C) with the TORX T20 bit.
NOTE: Before installing the mirror, remove the screw, and apply medium strength liquid thread lock to it.
2. Connect the rearview mirror connector (A).
3. Install the rearview mirror harness cover (A). Make sure the hooks (B, C) snap into place securely.
9. A-Pillar Trim - Check
1. If the side curtain airbag has deployed, replace the A-pillar trim (A), along with the other parts listed for side curtain airbag deployment.
2. If the side curtain airbag has not deployed, check the A-pillar trim and note the following items:
* To prevent the side curtain airbags from deploying improperly and possibly causing injury, inspect the A-pillar trim and replace it with a new one if it has any of the following damage:
- Any cracks, deformations, or stress-whitened areas in the A-pillar trim
- Any cracks or stress-whitening in the clip seating surfaces (B)
* After checking and adjusting the overlap between the headliner and the A-pillar trim, replace the upper clip (C) with a new one.
* If the clips (D) are damaged or stress-whitened, replace them with new ones.
10. Headliner/Pillar Trim Overlap - Check
Checking and Adjusting the Headliner/Pillar Trim Overlap
To prevent the side curtain airbag from deploying and damaging the pillar trim (A-pillar trim, B-pillar trim, quarter pillar trim), the overlap between the headliner and pillar trim must be 8.0+0/-2.0 mm (0.31+0/-0.08 in). To check the overlap, do this:
1. Install the headliner (A) and the pillar trim (B).
2. Apply masking tape (A) to the headliner (B) to mark the upper edge of the pillar trim (C).
3. Remove the pillar trim, and measure the headliner overlap.
* If the overlap is 8.0+0/-2.0 mm (0.31+0/-0.08 in), remove the tape, and install the pillar trim.
* If the overlap is more than 8.0 mm (0.31 in), go to step 4.
4. Carefully trim the headliner with a utility knife, reducing the overlap to 8.0+0/-2.0 mm (0.31+0/-0.08 in).
5. Remove the tape, and install the pillar trim.
11. A-Pillar Trim - Both Sides
NOTE: Repeat on the opposite side.
1. Carefully install a new upper clip (A) to the A-pillar trim (B).
2. Insert the bottom portion of the A-pillar trim (A) into the dashboard (B). Place the trim over the A-pillar (C), and fit its upper clip (D) and the other clips (E) into the holes (F) in the A-pillar, then lightly push the trim into place.
NOTE:
* Make sure the side curtain airbag is not tucked under the clips or the trim ribs.
* Do not push too hard on the A-pillar trim. If you push too hard, the clip will be damaged, and it will not hold the trim properly.
* Gently tug on the A-pillar trim to verify that all clips are securely fastened.
12. Front Door Opening Seal As Needed - Both Sides
1. Install the front door opening seal (A). Make sure the seal is installed securely into the hooks (B).
2. Repeat this step on the opposite side.
13. Center Cowl Cover
1. Install the center cowl cover (A). Make sure the clips (B) and the hooks (C) snap into place securely.
14. Side Cowl Cover - Both Sides
NOTE: Repeat on the opposite side.
1. Install the side cowl cover (A). Make sure the hooks (B) snap into place securely.
2. Right side; Install the windshield washer tube.
15. Cowl Top Cover - Both Sides
NOTE: Repeat this procedure on the opposite side.
1. Install the cowl top cover (A).
2. Install the hood rear seal (B).
3. Install the clip (C).
16. Front Fender Trim - Both Sides
NOTE: Repeat on the opposite side.
1. Install the front fender trim (A), then install the clips (B, C). Make sure the clips (D) snap into place securely.
17. Both Windshield Wiper Arm Assemblies
NOTE: Set the wiper arms to the auto-stop position before installation.
1. Install the wiper arms (A), the nut (B), and the caps (C).
18. Water Leak Test
Check for water leaks. Run water over the roof and on the sealing area as shown, and note these items:
* Use a 12 mm (0.47 in) diameter hose (A).
* Adjust the rate of water flow as shown.
* Do not use a nozzle.
* Hold the hose about 300 mm (12 in) away from the door.
19. Windshield Wiper Arm - Adjustment
1. Adjust the windshield wiper arms. Adjustments