Windshield: Service and Repair
Removal
1. Open the four A-pillar passenger assist handle covers.
2. Remove the two A-pillar passenger assist handles.
1. Remove the four bolts.
2. Remove the two A-pillar passenger assist handles.
3. Remove the two windshield side garnish mouldings.
4. Remove the overhead console.
5. Remove the two sun visors and two clips.
1. Remove the six screws.
2. Remove the sun visors and clips.
6. Remove the interior mirror.
7. Lower the front portion of the headliner.
8. Remove the cowl panel grille.
9. Using a soft brush or vacuum, remove any dirt or foreign material from the pinch weld.
NOTE: Lubricate the urethane adhesive with water to aid the special tool when cutting.
NOTE: Be sure not to scratch the pinch weld while removing windshield glass.
10. Using the special tool, cut the urethane adhesive from the windshield glass starting at the top center and working towards the bottom corners.
11. Using the special tool, distance the windshield from the body.
NOTE: Removing the windshield glass requires more than one technician.
12. Using the special tool, cut the remaining urethane adhesive and remove the windshield glass.
13. Using a soft brush or vacuum, remove any dirt and foreign material from the pinch weld.
Installation
CAUTION: After installing the urethane installed glass, the vehicle should not be driven until the urethane has cured. The curing time for temperatures above 13 °C (55 °F) and relative humidity above 50% is 12 - 24 hours. (See Drive Away chart for cure times as temperature and humidity vary). Inadequate curing of the urethane may adversely affect the strength of the urethane bond.
CAUTION: Open the windows to prevent the windshield glass from being pushed out by air pressure if doors are closed.
1. Dry fit the windshield. Make alignment marks with tape or non-staining pencil.
CAUTION: Do not scratch pinch weld area.
2. Trim the remaining urethane adhesive on the pinch weld to within specification. The surface should be smooth and free of cuts and contamination.
3. Use the wool applicator to apply metal primer to any exposed metal on the pinch weld. Allow six to ten minutes to dry.
4. If reinstalling the original windshield, remove excess urethane adhesive from the windshield glass.
5. Clean the inside of the glass surface with an alcohol-free cleaner making sure the ceramic-coated area is clean.
CAUTION: Wipe off urethane glass prep immediately after each application because it flash dries.
6. If installing a new windshield, apply glass prep twice around the glass surface.
7. If installing a new windshield, apply glass primer to the same area that was propped in the previous step. Allow five minutes to dry.
8. Apply foam dam to the bottom of the windshield glass.
9. Cut the urethane applicator tip to specification.
10. Apply a bead of urethane adhesive to the sides and top of the windshield glass.
11. Apply a bead of urethane adhesive to the bottom of the windshield glass outside the foam dam.
12. Install the windshield by aligning it to the marks previously made.
CAUTION: Carry out this step after the urethane has cured.
13. Check the windshield glass installation for air or water leaks through the urethane seal.
14. If necessary, remove excess urethane adhesive from the outside surface of the windshield glass.
15. Install the cowl grille.
16. Reposition the front portion of the headliner.
17. Install the overhead console.
1. Position the overhead console. If equipped, connect the electrical connector.
2. Install the screws.
18. Install the two sunvisor clips
1. Position the sun visors and clips.
2. Install the six screws.
19. Install the rear view mirror.
20. Install the two windshield side garnish mouldings.
21. Install the two A - pillar passenger assist handles.
1. Position the two assist handles.
2. Install the four bolts.
3. Close the four assist handle covers.
22. Install the driver and passenger assist handles.