Windshield: Service and Repair

WINDSHIELD GLASS REMOVAL/INSTALLATION









Removal

WARNING:Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury.

WARNING: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.
1. Remove the LH and RH A-pillar trim panels. See - Locations.

2. Remove the 2 windshield side garnish mouldings.





3. Open the front overhead console door, remove the 2 screws and the overhead console.

- If equipped, disconnect the electrical connector.

4. Remove the interior rear view mirror. See - Exterior Rear View Mirrors - Principles Of Operation.

5. Remove the LH and RH sun visors and visor clips.

- If equipped, disconnect the electrical connectors.

6. Partially lower the front portion of the headliner and block with a suitable material.

7. Remove the cowl panel grille. See Service and Repair.

8. Using a soft brush or vacuum, remove any dirt or foreign material from the pinch weld.





9. Using the special tool, cut the urethane adhesive from the windshield glass starting at the top center and working toward the bottom corners.

NOTE:Lubricate the urethane adhesive with water to aid the special tool when cutting.






10. Using the special tool, distance the windshield glass from the body.

11. Using the special tool, cut the remaining urethane adhesive and remove the windshield glass.

12. Using a soft brush or vacuum, remove any foreign material or dirt from the pinch weld.

Installation

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:Open the windows to prevent the windshield glass from being pushed out by air pressure if the doors are closed.

WARNING:Open the windows to prevent the windshield glass from being pushed out by air pressure if the doors are closed.
1. Dry fit the windshield glass, making alignment marks with tape or a non-staining grease pencil.





2. Trim the remaining urethane adhesive on the pinch weld to within the specification.

- The existing urethane adhesive surface should be smooth and free of cuts and contamination.

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:Do not scratch the pinch weld area. For minor scratches or exposed metal on the pinch weld, see manufacturer's recommendations.
3. If reinstalling the original windshield glass, remove the excess urethane adhesive and the windshield moulding.

4. Clean the inside of the windshield glass surface with glass cleaner making sure the ceramic-coated area is clean.

5. If installing a new windshield glass, apply urethane glass primer according to manufacturer's instructions. Allow at least 6 minutes to dry.

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. See the Material Chart in this procedure.
NOTE:Sika uses the same black primer for the glass and pinch weld area.






6. Cut the urethane adhesive applicator tip to specification.

7. 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.

NOTE:Use either a high-ratio electric or battery-operated caulk gun that will apply the urethane with less effort and a continuous bead.
8. Install the windshield glass, aligning it to the marks previously made.

9. After the urethane adhesive has cured, check for water leaks and add urethane adhesive where needed.

NOTE:The urethane adhesive must cure for a minimum of one hour before testing for air and water leaks.
10. If necessary, remove excess urethane adhesive from the exterior surface of the windshield glass.

11. Install the cowl grille. See Service and Repair.

12. Reposition the front portion of the headliner.

13. Install the LH and RH sun visors and visor clips.

- If equipped, connect the electrical connectors.

14. Install the interior rear view mirror. See - Exterior Rear View Mirrors - Principles Of Operation.

15. Position the overhead console and install the 2 overhead console screws.

- If equipped, connect the electrical connector.

16. Install the 2 windshield side garnish mouldings.

17. Install the LH and RH A-pillar trim panels. See - Locations.