Removal and Replacement

WINDSHIELD GLASS

Special Tool(s):

Special Tool(s)

Materials:

Material







Removal

WARNING: To prevent glass splinters from entering the eyes or cutting the hands, wear safety glasses and heavy gloves when cutting the glass from the vehicle.

1. Remove the windshield wiper arms.
2. Remove the cowl grille panel.
3. Drill out the rivets and remove the windshield glass stops.
4. Remove the inside rear view mirror.
5. Remove the RH and LH A-pillar trim panels.
6. Lower the front portion of the headliner.







7. CAUTION: To prevent damage to the windshield header seal, turn the blade so that the flat side is against the pinch weld.

NOTE:
- Lubricate the existing urethane adhesive with water to aid the special tool while cutting.
- Removing the windshield glass requires more than one technician.

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







8. Using the special tool, distance the windshield glass from the body.
9. Using the special tool, cut the remaining urethane adhesive and remove the windshield glass.
10. Using a soft brush or vacuum, remove any dirt or foreign material from the pinch weld.
11. Remove the windshield header seal.

Installation

CAUTION: When installing urethane installed glass parts, the vehicle must not be driven until the urethane adhesive has cured. Refer to drive away chart for the cure times, as temperatures and humidity will cause cure times to vary. Inadequate or incorrect curing can adversely affect the bonding of the windshield glass.







1. Trim the remaining urethane on the pinch weld to within specification. The urethane adhesive must be smooth and free of cuts and contamination after trimming. Avoid touching the urethane adhesive after preparation
2. Check the pinch weld for damaged or raised sheet metal at the spot welds, or rust, and repair any obvious concerns.







3. Install the windshield glass stops on the vehicle.
- Using the special tool, rivet the stops in position.

4. If re-installing the original windshield glass, remove all remaining traces of urethane sealant from the glass.
5. Install the windshield header seal on the windshield glass.
6. Clean the inside of the windshield glass with glass cleaner.

7. CAUTION: 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. Refer to the Material Chart in this procedure.

NOTE: Sika uses the same black primer for the glass and pinch weld area.

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







8. NOTE: Use either a high-ratio, electric or battery-operated caulk gun that will apply the urethane with less effort and continuous bead. 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.







9. CAUTION: After replacing the urethane-installed glass, the vehicle must not be driven until the urethane has cured. Inadequate curing of the urethane can adversely affect the strength of the urethane sealant bond.

NOTE: Before installing the windshield glass, open the windows to prevent the windshield glass from being pushed out by air pressure if a door is closed.

Install the windshield glass.

10. Fill the cavities between both the LH and RH sides of the windshield header seal and the sheet metal, using urethane adhesive for a total length of 50 mm (1.96 in) from the base of the A-pillars.
11. Install the inside rear view mirror.
12. Install the roof trim panel.
13. Install the LH and RH A-pillar mouldings.
14. Install the cowl grille panel.
15. Install the windshield wiper arms.