Windshield Removal/Installation
REMOVALNot Reusing Windshield
1. Disconnect the negative battery cable.
2. Remove the sunroof switch.
3. Remove the interior and spot light.
4. Remove the sunvisor and adapter.
5. Remove the rearview mirror.
6. Remove the A-pillar trim.
7. Remove the windshield molding.
8. Remove the windshield wiper arm and blade.
9. Remove the cowl grille.
10. Apply protective tape along the edge of the body to protect it from damage.
11. Use a tool like that shown in the figure and insert the blade into the sealant.
12. Pull it through the sealant around the edge of the glass.
13. Remove the glass.
Reusing Windshield
1. Disconnect the negative battery cable.
2. Remove the sunroof switch..
3. Remove the interior and spot light.
4. Remove the sunvisor and adapter.
5. Remove the rearview mirror.
6. Remove the A-pillar trim.
7. Remove he windshield molding.
8. Remove the windshield wiper arm and blade.
9. Remove the cowl grille.
10. Apply protective tape along the edge of the body to protect it from damage.
11. Apply protective tape along the front edge of the headliner and the dashboard to protect them from damage.
12. Make a hole through the sealant from the inside of the vehicle by using an awl.
13. Pass the SST (piano wire) through the hole.
14. Wind each end of the wire around a bar.
15. Working with another person, saw through the sealant around the edge of the glass. Use a long sawing action to spread the work over the whole length of wire to prevent it from breaking. Make sure the wire does not rub on the body or the dashboard.
16. Remove the glass.
17. Remove the spacers and dam.
INSTALLATION
1. Cut away the old sealant by using a razor knife so that 1 to 2 mm { 0.04 to 0.08 in } of 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 apply new sealant to create a 2 mm {0.08 in} layer.
2. Carefully clean an area 50 mm { 1.97 in } wide around the circumference of the glass and clean the bonding area on the body.
3. Securely bond a new dam along the top and sides 8 mm { 0.31 in } from the edge of the glass as shown. Allow it to dry completely.
4. Install the spacers B onto the glass as shown.
5. Install the spacers A onto the body as shown.
6. Set the glass onto the body and adjust the clearance between the top of the glass and the body to 8 mm (0.31 in } by moving the spacers up or down.
7. Make a mark on the glass directly above the V-notch of spacers A.
8. Remove the glass from the body.
9. Apply primer to the bonding area of the glass and body by using a brush. Keep the area free of dirt and grease, and do not touch the surface. Allow it to dry for approximately 30 minutes.
10. After the primer has dried, apply an 11 mm { 0.43 in } high bead of sealant around the entire circumference of the glass as shown. Keep the bead of sealant smooth and even, shaping it with a spatula where necessary. If the windshield is being reused, apply new sealant over the original.
11. Align the glass marks with the notches in the spacers and install the glass onto the body.
12. Press firmly on the glass to compress the sealant. Verify that the clearance between the top and sides of the glass and the body is 8 mm { 0.31 in }.
13. To prevent the glass from being pushed out by air pressure if a door is closed, open all of the windows until the sealant has hardened.
14. Use a scraper to smooth away any sealant that oozes out. Add more sealant to any points of poor contact. Adjust the upper and side sealants as shown, if necessary.
15. Before the surface of the sealant has hardened, install the windshield molding.
Hardening time of sealant
16. Inspect for water leaks.
17. If a leak is found, wipe the water off well and add sealant where needed.
18. Install the cowl grille.
19. Install the windshield wiper arm and blade.
20. Install the A-pillar trim.
21. Install the rearview mirror.
22. Install the sunvisor and adapter.
23. Install the interior and spot light.
24. Install the sunroof switch.