Windshield Glass
Windshield Glass
Removal
1. Remove the cowl panel grille. For additional information, refer to Front End Body Panels Service and Repair.
2. Remove the interior rear view mirror. For additional information, refer to Rear View Mirrors 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. Before cutting the urethane adhesive, remove dirt and other foreign material from the windshield pinch weld area.
- Use a clean shop towel or oil-free compressed air.
9. NOTE: Refer to manufacturer's instructions before using the Deluxe Windshield Removal Tool.
Lubricate the urethane adhesive with water to aid the Deluxe Windshield Removal Tool when cutting the urethane adhesive.
10. 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.
NOTICE: To avoid rust formation, use extreme care not to scratch the paint or primer, or otherwise damage the pinch weld during glass removal.
NOTE: Insert the blade into the Deluxe Windshield Removal Tool so that the flat side is against the glass. This will leave the entire urethane adhesive bead on the pinch weld and allow a dry fit of the replacement windshield glass.
Using the Deluxe Windshield Removal Tool, cut the urethane adhesive from the windshield glass starting at the top center and working toward the bottom corners.
11. Using The Pumper, distance the windshield glass from the body.
12. Using the Deluxe Windshield Removal Tool, cut the remaining urethane adhesive and remove the windshield glass.
13. Carefully remove the windshield glass from the vehicle and place on a stable work surface.
Installation
1. Dry-fit the new windshield glass on the existing urethane adhesive bead on the pinch weld.
- Position the windshield glass on the pinch weld.
- Center the windshield glass in the opening.
- Adjust the windshield glass stop blocks (if equipped) as needed for best fit.
- Make alignment marks with tape or non-staining grease pencil (preferably at the windshield glass stop blocks if equipped) on the windshield glass and the body.
2. After the dry-fit alignment, remove the glass from the windshield opening and place on a stable work surface with the interior side of the glass facing up.
3. 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: Avoid scratching the pinch weld. Repair all minor scratches or exposed metal on the pinch weld following manufacturer's instructions. Use the same brand pinch weld primer, glass primer and urethane adhesive.
Using an appropriate tool, trim the urethane adhesive leaving a 1-2 mm (0.04-0.08 in) base of the original equipment urethane adhesive on the pinch weld.
4. Using a clean shop towel, brush or oil-free compressed air, clean the pinch weld area around the existing urethane adhesive. Remove any foreign material or water that may have entered during windshield removal.
5. If reinstalling the same windshield glass, remove the remaining urethane adhesive from the glass leaving a thin layer to bond with the new urethane adhesive bead.
6. 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.
7. Clean the windshield glass with glass cleaner.
8. NOTE: Be sure to use the same brand and cure-rate products for the urethane adhesive and glass primer. Do not mix different brands of urethane adhesive and glass primer. Refer to the Material Chart in this procedure.
If installing a new windshield glass, apply glass primer according to the manufacturer's instructions. Allow at least 6 minutes to dry.
9. Cut the urethane adhesive applicator tip to specification.
10. NOTE: The windshield glass must be positioned within 10 minutes of applying the urethane adhesive.
NOTE: Use either a high-ratio, electric or battery-operated caulk gun that applies the urethane adhesive with less effort and continuous bead.
Apply urethane adhesive on top of the existing trimmed urethane adhesive bead on the pinch weld, starting and ending at the bottom of the windshield glass near the center, making sure there are no gaps in the bead.
11. WARNING: Do not drive vehicle until the urethane adhesive seal has cured. Follow urethane adhesive manufacturer's curing directions. Inadequate or incorrect curing of the urethane adhesive seal will adversely affect glass retention. Failure to follow these instructions may result in serious injury to vehicle occupant(s).
NOTICE: Before positioning the windshield glass, open vehicle windows to prevent the air pressure of closing doors from affecting the adhesive bond.
Install the windshield glass aligning it to the marks made previously.
12. NOTE: The urethane adhesive must cure for a minimum of one hour before testing for air or water leaks.
After the urethane adhesive cures, check the windshield glass seal for air or water leaks through the urethane adhesive bead and add urethane adhesive as necessary.
13. Position the front portion of the headliner.
14. Install the sun visors and sun visor clips.
15. Install the LH and RH A-pillar trim panels.
16. Install the front door weatherstrips.
17. Install the instrument panel defroster opening grille.
- Connect the electrical connectors.
18. Install the interior rear view mirror. For additional information, refer to Rear View Mirrors Interior Rear View Mirror.
19. Install the cowl panel grille. For additional information refer to Front End Body Panels Service and Repair.