Windshield: Service and Repair
WINDSHIELD REMOVAL1. Remove the rearview mirror.
2. Remove the cowl grille.
3. Remove the headliner.
4. Apply protective tape along the edge of the body to protect it from damage.
5. Apply protective tape to the dashboard to protect it from damage.
WARNING: Using a razor with bare hands can cause injury. Always wear gloves when using a razor.
NOTE: The windshield molding is a replacement part.
6. Cut the lip of the windshield molding using a razor.
Not Reusing Windshield
1. Remove the base.
NOTE: For the areas of the sealant that are difficult to cut, use a SST (piano wire) and follow the procedure under "Reusing Windshield".
2. Use a tool like that shown in the figure, and insert the blade into the sealant.
3. Pull through the sealant around the edge of the glass.
4. Remove the glass.
Reusing Windshield
NOTE: Before removing the windshield from the body, mark the position of the windshield by affixing tape to the windshield and body panel.
1. Make a hole through the sealant except fasteners from the inside of the vehicle using an awl.
WARNING: Using a SST (piano wire) with bare hands can cause injury. Always wear gloves when using a SST (piano wire).
2. Pass the SST (piano wire) through the hole.
3. Wind each end of the SST (piano wire) around a bar.
NOTE: Use a long sawing action to spread the work over the whole length of the SST (piano wire) to prevent it from breaking.
4. Working with another person, saw through the sealant around the edge of the glass.
5. Remove the windshield.
6. Remove the dam from the windshield.
7. Remove the fasteners.
8. Remove spacers.
WINDSHIELD INSTALLATION
WARNING: Using a razor with bare hands can cause injury. Always wear gloves when using a razor.
CAUTION: To prevent the sealant from cracking or the glass from being pushed out by air pressure if a door is closed, open all of the windows and leave them open until the sealant has hardened.
1. Cut away the old sealant using a razor 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 2 mm {0.08 in} layer.
2. Clean and degrease an approximately 50.0 mm {1.97 in} wide strip around the circumference of the glass and the bonding area on the body.
3. Securely bond a dam along the circumference of the glass 8.5 mm {0.33 in} from the edge.
4. Install the fasteners on the glass marks as shown.
5. Install spacers into the hole.
6. Align the front windshield molding with the edge of the glass. (1)
7. Install the front windshield molding in the direction shown by the arrow. (2)
8. Temporarily install the glass onto the body and adjust the glass-to-body clearance.
9. Make a mark on the glass directly above the V-notch of spacers.
10. Remove the windshield.
11. Paste the fasteners on the body as shown.
CAUTION: Keep the area free of dirt and grease, and do not touch the surface or the primer may not properly bond to the surface of the glass and body, which may cause leaks to occur.
12. Use a brush to apply primer to the bonding area of the glass, the body, and the molding within the region shown.
NOTE: Use only glass primer on the glass, and body primer on the body and the molding. Allow it to dry for approximately 30 minutes.
13. Once the primer is dry, apply sealant around the entire circumference to fill the gap between the dam and the edge of the glass measuring 11.0 mm {0.43 in} high and 5.0 mm {0.20 in} wide.
14. Align the glass marks with the V-notches in spacers and install the glass onto the body.
15. Press firmly inward on the glass to compress the sealant.
16. Verify that the gap along the upper edge is 4.9 mm {0.19 in} and side edge is 4.4 mm {0.17 in}.
17. Use a scraper to smooth away any sealant that oozes out. Add more sealant to any points of poor contact. Adjust the sealant as shown if necessary.
18. Use isopropyl alcohol to remove any excess sealant.
19. Install the headliner.
20. Install the cowl grille.
21. Install the base.
22. Install the rearview mirror.