Windshield: Service and Repair

Removal

CAUTION:
- Wear gloves to remove and install the windshield.
- Use covers to avoid damaging any surfaces.

1. To remove the windshield, first remove the:
- Seats
- Rearview mirror
- Sunvisors
- Front pillar retainer
- Front wiper and air scoop
- Front pillar trim and headliner

2. Peel off the upper molding.




3. Apply protective tape along the edge of the dashboard and body next to the windshield as shown.




4. Using an awl, make a hole through the adhesive from inside the car. Push piano wire through the hole, and wrap each end around a piece of wood.
5. With a helper on the outside, pull the piano wire back and forth in a sawing motion and carefully cut through the adhesive around the entire windshield.






CAUTION:
- Hold the piano wire as close to the windshield as possible to prevent damage to the body and dashboard.
- Take care not to damage the vehicle identification number plate.

6. Cut the lower spacers and upper fastener away from the body with a knife; they are cemented in place.

NOTE: Replace the lower spacers with new ones whenever the windshield has been removed.

Installation

1. Scrape the old adhesive smooth with a knife to a thickness of about 2 mm (0.08 in.) on the bonding surface around the entire windshield flange.

NOTE:
- Do not scrape down to the painted surface of the body; damaged paint will interfere with proper bonding.
- Remove all traces of the lower spacer material from the body.
- Mask off surrounding surfaces before painting.

2. Clean the body bonding surface with a sponge dampened in alcohol.

NOTE: After cleaning, keep oil, grease or water from getting on the surface.

3. If the old windshield is to be reinstalled, use a putty knife to scrape off all traces of old adhesive, then clean the windshield surface with alcohol where new adhesive is to be applied.

NOTE: Make sure the bonding surface is kept free of water, oil and grease.






CAUTION: Avoid setting the windshield on its edges; small chips may later develop into cracks.




4. Glue the lower spacers and defrost panel seals in place as shown.




5. Set the windshield upright on the lower spacers, then center it in the opening. Make alignment marks by marking lines across the windshield and body with a grease pencil at the four points shown.

6. Glue the rubber dam to the inside face of the windshield, as shown, to contain the adhesive during installation.






NOTE: Be careful not to touch the windshield where adhesive will be applied.

7. With a sponge, apply a light coat of glass primer around the edge of the windshield as shown, then lightly wipe it off with gauze or cheesecloth.






NOTE:
- Do not apply body primer to the windshield, and do not get body and glass primer sponges mixed up.
- Never touch the primed surfaces with your hands. If you do, the adhesive may not bond to the windshield properly, causing a leak after the windshield is installed.
- Keep water, dust, and abrasive materials away from the primed surface.

8. Thoroughly mix all the adhesive and hardener together on a glass or metal plate with a putty knife.

NOTE:
- Clean the plate with a sponge and alcohol before mixing.
- Follow the instructions that come with the adhesive.




9. Before filling a cartridge, cut the end of the nozzle as shown.
10. Pack adhesive into the cartridge without air pockets to ensure continuous delivery. Put the cartridge in a calking gun, and run a bead of adhesive around the edge of the windshield as shown.






NOTE: Apply the adhesive within thirty minutes after applying the glass primer.

11. With a sponge, apply a light coat of body primer to the original adhesive remaining around the windshield flange. The windshield should be installed 10 minutes after you apply the primer.






NOTE:
- Do not apply glass primer to the body, and be careful not to mix up glass and body primer sponges.
- Never touch the primed surfaces with your hands.
- Mask off the dashboard before painting the flange.




12. Glue the upper fastener to the body as shown.
13. Use suction cups to hold the windshield over the opening, align it with the alignment marks made in step 5 and set it down on the adhesive. Lightly push on the windshield until its edges are fully seated on the adhesive all the way around.






NOTE: Do not close or open the doors until the adhesive is dry.




14. Install the upper molding.
15. Let the adhesive dry for at least one hour, then spray water over the windshield and check for leaks. Mark leaking areas and let the windshield dry, then seal with urethane windshield adhesive.

NOTE:
- Let the car stand for at least four hours after windshield installation. If the car has to be used within the first four hours, it must be driven slowly.
- Keep the windshield dry within the first hour after installation.
- Check that the ends of the front pillar retainer are set under the air scoop.

16. Reassemble all removed parts.