Windshield Removal/Installation
REMOVALNot Reusing Windshield
1. Remove the rearview mirror.
2. Remove the A-pillar trim.
3. Remove the cowl grille.
4. Remove the windshield molding.
5. Apply protective tape along the edge of the body to protect it from damage.
6. Remove the sunvisor, and apply protective tape along the edge of the headliner to protect it from damage.
7. Apply protective tape to the dashboard to protect it from damage.
NOTE: For the areas of the sealant that are difficult to cut, use a piano wire and follow the procedures under "Reusing Windshield".
8. Use a tool like that shown in the figure, and insert the blade into the sealant.
9. Pull through the sealant around the edge of the glass.
10. Remove the glass.
Reusing Windshield
1. Remove the rearview mirror.
2. Remove the A-pillar trim.
3. Remove the cowl grille.
4. Remove the windshield moding.
5. Apply protective tape along the edge of the body to protect it from damage.
6. Remove the sunvisor, and apply protective tape along the edge of the headliner to protect it from damage.
7. Apply protective tape to the dashboard to protect it from damage.
8. Make a hole through the sealant from the inside of the vehicle by using an awl.
9. Pass the SST (piano wire) through the hole.
10. Wind each end of the wire around a bar.
NOTE: Use the entire length of piano wire to prevent it from breaking when cutting through the sealant.
11. Working with another person, saw through the sealant around the edge of the glass, being careful to not damage the vehicle body or the dash board.
12. Remove the windshield.
13. Remove the spacers and dam.
INSTALLATION
CAUTION: To prevent the sealant from cracking or the glass from being pushed out by air pressure if a door is closed, open all of the windows and leave them open until the sealant has hardened.
1. Cut away the old sealant by using a razor knife so that 1-2 mm {0.04-0.07 in} thickness of a sealant remains around the circumference of the frame. If all the sealant has come off in any one place, apply some primer after degreasing, and allow it 30 minutes to dry. Then put on new sealant to create a 2 mm {0.08 in} layer.
2. Clean and degrease an approximately 50 mm {2.0 in} wide strip around the circumference of the glass and the bonding area on the body.
3. Securely bond a dam along the circumference of the glass 8 mm {0.3 in}.
4. Install spacers into the holes.
5. Temporarily install the glass onto the body and adjust the glass-to-body clearance.
6. Make a mark on the glass directly above the V-notch of spacers.
7. Verify that the gap along the upper and sides are 7.3 mm {0.29 in}.
8. Remove the windshield.
CAUTION: Keep the area free of dirt and grease, and do not touch the surface or the primer may not properly bond to the surface of the glass and body which may cause leaks to occur.
9. Use a brush to apply primer to the bonding area of the glass and body within the region shown. Use only glass primer on the glass and body primer on the body and molding. Allow it to dry for approximately 30 minutes.
10. Once the primer is dry, apply sealant around the entire circumference to fill the gap between the dam and the edge of the glass with a 11-13 mm {0.44-0.51 in} high 5 mm {0.2 in} wide bead of sealant.
11. Align the glass marks with the V-notches in spacers and install the glass onto the body.
12. Press firmly inward on the glass to compress the sealant.
13. Verify that the gap along both the upper and sides are 7.3 mm {0.29 in}.
14. Use a scraper to smooth away any sealant that oozes out. Add more sealant to any points of poor contact. Adjust the sealant as shown if necessary.
15. Before the surface of the sealant has hardened, install the windshield molding.
16. Use white gasoline to remove any sealant that oozes out.
17. Check for water leaks. If a leak is found, wipe the water off well and add sealant where needed.
18. Install the sunvisor.
19. Install the cowl grille.
20. Install the A-pillar trim.
21. Install the rearview mirror.