WINDSHIELD INSTALLATION

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Warning

•  Using a utility knife with bare hands can cause injury. Always wear gloves when using a utility knife.

Caution

•  If a door is opened or closed when all the window glass is closed, the resulting change in air pressure could cause the sealant to crack preventing the proper installation of the windshield. Keep the door glass opened until the windshield installation is completed.

1.  Remove the sealant along the perimeter of the glass using a utility knife. (When reusing the glass)

2.  Clean and degrease an approx. 50 mm {2.0 in} wide strip along the perimeter of the windshield.

3.  Inspect the glass for cracks. If it is cracked, chamfer it using sandpaper.

4.  Align the alignment marks made before removal and install the pin to the windshield referring to the figure. (Reusing glass, pin removed)

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5.  Install the windshield molding.

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6.  Apply glass primer on the glass as shown in the figure, then allow it to dry for approx. 30 min.

Caution

•  To prevent weakening of the primer adhesion, keep the bonding surface free of dirt, moisture, and grease. Do not touch the surface with your hand.

Note

•  Apply primer to the hollowed marks in the ceramic coating.

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7.  Cut away the old sealant using a utility knife so that 1—2 mm {0.04—0.07 in} thickness of sealant remains along the perimeter of the frame.

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8.  If the sealant has come off completely in any one place, apply some primer after degreasing, and allow it approx. 30 min to dry. Then apply 2 mm {0.08 in} thickness of new sealant.

Caution

•  To prevent weakening of the primer adhesion, keep the bonding surface free of dirt, moisture, and grease. Do not touch the surface with your hand.

9.  Clean and degrease along the perimeter of the bonding area on the body.

10.  Apply body primer on the body as shown in the figure, then allow it to dry for approx. 30 min.

Caution

•  To prevent weakening of the primer adhesion, keep the bonding surface free of dirt, moisture, and grease. Do not touch the surface with your hand.

Note

•  Apply primer to the hollowed marks in the ceramic coating.

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11.  Apply sealant to the area of the glass surface as shown in the figure.

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12.  Insert the positioning pins to the body and install the windshield.

13.  Verify that the clearance between the A-pillar and the roof is within the range shown in the figure, and press along the perimeter of the glass.

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14.  Install the headliner.

15.  Install the following parts (vehicles with heated windshield):

(1)  Install the clip A.

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(2)  Connect the connector.

(3)  Set the flat cable at the bottom of fender bolt.

(4)  Install the harness from clip B (L.H.D.).

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(5)  Install the fastener (R.H.D.).

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(6)  Install the clip C.

(7)  Install the bolt A.

(8)  Install the fastener (L.H.D.).

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(9)  Set the flat cable under the fender bolt.

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(10)  Attach the taped area of the wiring harness to clip B. (R.H.D.)

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(11)  Assemble the harness place where under the cross member as shown in the figure.

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(12)  Install the clip D.

(13)  Install the bolt B.

16.  Install the following parts:

(1)  Assist handle (See ASSIST HANDLE REMOVAL/INSTALLATION.)

(2)  Sunvisor (See SUNVISOR REMOVAL/INSTALLATION.)

(3)  A-pillar trim (See A-PILLAR TRIM REMOVAL/INSTALLATION.)

(4)  Rear view mirror (Vehicles without auto-dimming mirror) (See REARVIEW MIRROR INSTALLATION.)

(5)  Auto-dimming mirror (Vehicles with auto-dimming mirror) (See AUTO-DIMMING MIRROR INSTALLATION.)

(6)  Rain sensor (Vehicles with auto light / wiper system) (See RAIN SENSOR REMOVAL/INSTALLATION.)

(7)  Cowl grille (See COWL GRILLE REMOVAL/INSTALLATION.)

(8)  Windshield wiper arm and blade (See WINDSHIELD WIPER ARM AND BLADE REMOVAL/INSTALLATION.)

17.  Connect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [MZR 2.0, MZR 2.5].) (See BATTERY REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo].) (See BATTERY REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop].) (See BATTERY REMOVAL/INSTALLATION [MZ-CD 1.6].) (See BATTERY REMOVAL/INSTALLATION [MZR-CD 2.2].) (See BATTERY REMOVAL/INSTALLATION [SKYACTIV-G 2.0].) (See BATTERY REMOVAL/INSTALLATION [MZR 1.5, MZR 1.6].)

18.  Allow the sealant to harden completely.