Removal and Replacement

WINDSHIELD GLASS

Special Tool(s):

Special Tool(s)







Removal

WARNING: To prevent glass splinters from entering the eyes or cutting hands, wear safety glasses and heavy gloves when cutting the glass from the vehicle. Failure to follow these instructions may result in personal injury.

1. Remove the cowl panel grille.
2. Remove the interior rear view mirror.
3. Remove the instrument panel defroster opening grille from the instrument panel.
- Disconnect the electrical connectors.

4. Partially remove the front door weatherstrips.
5. Remove the LH and RH A-pillar trim panels.
6. Remove the LH and RH sun visors and sun visor clips.
7. Lower the front portion of the headliner.







8. NOTE: Lubricate the existing urethane adhesive with water to aid the special tool while cutting.

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







9. CAUTION: When inflating the special tool, be careful not to over-stress the windshield glass, as this causes breakage.

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







10. Using the special tool, cut the remaining urethane adhesive and remove the windshield glass.
11. Using a soft brush or vacuum, remove any dirt or foreign material from the pinch weld area.

Installation

CAUTION: When installing urethane-installed glass parts, the vehicle must not be driven until the urethane adhesive has cured. Adequate cure time is specified on the drive away chart for each urethane product as temperatures and humidity vary. Inadequate or incorrect curing can adversely affect the retention of the windshield glass.

NOTE: For additional material guidelines, refer to the manufacturer's installation information.

1. Dry fit the windshield glass. Make alignment marks on glass and sheet metal with tape or non-staining grease pencil.
2. Remove the windshield glass.







3. NOTE: Avoid scratching the pinch weld. For minor scratches or exposed metal on the pinch weld, see the manufacturer's recommendations.

Using an appropriate tool, trim the urethane adhesive leaving a 1-2 mm (0.04-0.08 in.) base of the original equipment on the pinch weld.

4. If reinstalling the original windshield glass, remove the excess urethane adhesive from the windshield glass.

5. NOTE: If the moulding is already on the windshield glass, proceed to the next step.

Align the "V" notch in the ceramic paint and windshield moulding at top center. Fully seat the windshield moulding along the top edge of the windshield glass and along the sides and bottom edges of the windshield glass.

6. Clean the windshield glass with a non-alcohol based window 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.

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 the manufacturer's instructions. Allow at least 6 minutes to dry.







8. Cut the urethane adhesive applicator tip to specification.







9. NOTE: Use either a high-ratio, electric or battery-operated caulk gun that applies 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 glass near the center.

10. Install the windshield glass aligning it to the marks made previously.

11. CAUTION: When installing urethane-installed glass parts, the vehicle must not be driven until the urethane has cured. Adequate cure time is specified on the drive away chart for each urethane product as the temperatures and humidity vary. Inadequate or incorrect curing can adversely affect the retention of the windshield glass.

NOTE: The urethane adhesive must cure for a minimum of 1 hour before testing for air or water leaks.

After the urethane cures, check the windshield glass seal for air or water leaks through the urethane adhesive bead and add urethane adhesive as necessary.

12. Position the front portion of the headliner.
13. Install the sun visors and sun visor clips.
14. Install the LH and RH A-pillar trim panels.
15. Install the front door weatherstrips.
16. Install the instrument panel defroster opening grille.
- Connect the electrical connectors.

17. Install the interior rear view mirror.
18. Install the cowl panel grille.