Windshield Removal/Installation
REMOVALIf The Glass Will Not Be Reused
1. Remove the windshield upper molding.
2. Remove the windshield lower molding.
3. Remove the rearview mirror.
4. Remove the A-pillar trim.
5. Remove the grommets as shown.
6. Apply protective tape along the edge of the body to protect it from damage.
7. Use a tool like that shown in the figure, and insert the blade into the sealant.
8. Pull through the sealant around the edge of the glass.
9. Remove the glass.
10. Remove the spacers from the body.
If The Glass Will Be Reused
1. Remove the windshield upper molding.
2. Remove the windshield lower molding.
3. Remove the rearview mirror.
4. Remove the A-pillar trim.
5. Remove the grommets as shown.
6. Apply protective tape along the edge of the body to protect it from damage.
7. Remove the front header trim.
8. Use protective tape or cloth along the front edge of the headliner to protect it from damage.
9. Make a hole through the sealant from the inside of the vehicle by using an awl.
10. Pass piano wire through the hole.
11. Wind each end of the wire around a bar.
12. Working with another person, saw through the sealant around the edge of the glass. Use a long sawing action to spread the work over the whole length of wire to prevent it from breaking.
13. Remove the glass.
14. Remove the spacers from the body.
15. Remove the dam from the body.
INSTALLATION
1. Cut away the old sealant by using a razor knife so that 1 - 2 mm (0.04 - 0.07 in} thickness of sealant remains around the circumference of the frame. If all the sealant has come off in any one place, apply some primer after degreasing, and allow it 30 minutes to dry. Then put on new sealant to create a 2mm {0.08 in} layer.
2. Clean and degrease around the circumference of the glass and the bonding area on the body.
3. Security bond a dam along the circumference of the glass 7 mm {0.28 in} from the edge. Allow it to dry completely.
4. Install the spacers onto the body as shown.
5. Temporarily install the glass onto the body and make marks on the glass directly above the V-notches of the spacers.
6. Remove the glass.
CAUTION: Keep the area free of dirt and grease, and do not touch the surface or the primer and sealant will not properly bond to the glass and body, causing leaks to occur.
7. Use a brush to apply primer to the bonding area of the glass and the body. Allow it to dry for approximately 30 minutes.
8. Prepare the nozzle of the sealant tube so that it has a flange that can run along the edge of the glass and a V from which the sealant can flow. Once the primer is dry, apply sealant around the entire circumference to fill the gap between the dam and the edge of the glass with a 12 mm (0.47 in) high bead of sealant. Keep the bead of sealant smooth and even, reshaping it where necessary by using a spatula.
9. Align the glass marks with the V notches in the spacers and install the glass onto the body.
10. Press firmly inward on the glass to compress the sealant.
11. Use a spacer to smooth away any sealant that oozes out. Add more sealant to any points of poor contact.
12. To prevent the glass from being pushed out by air pressure if a door is closed, open all of the windows until the sealant has hardened.
Hardening time of sealant
13. Check for water leaks. If a leak is found, wipe the water off well and add sealant where needed.
14. Install the A-pillar trim.
15. Install the rearview mirror.
16. Install the windshield lower molding.
17. Install the windshield upper molding.