Windshield: Service and Repair
WINDSHIELD REMOVAL1. Remove the rearview mirror.
2. Remove the cowl grille.
3. Remove the headliner.
4. Apply protective tape along the edge of the body to protect it from damage.
5. Apply protective tape to the dashboard to protect it from damage.
6. Cut the lip of the windshield molding using a razor.
WARNING: Using a razor with bare hands can cause injury. Always wear gloves when using a razor.
NOTE: The windshield molding is a replacement part.
Not Reusing Windshield
1. Remove the base.
2. Use a tool like that shown in the figure, and insert the blade into the sealant.
NOTE: For the areas of the sealant that are difficult to cut, use the SST (piano wire) and follow the procedures under '"Reusing Windshield".
3. Pull through the sealant around the edge of the glass.
4. Remove the glass.
Reusing Windshield
NOTE: Before removing the windshield from the body, mark the position of the windshield by affixing tape to the windshield and body panel.
1. Make a hole through the sealant except fasteners and spacers from the inside of the vehicle using an awl.
2. Pass the SST (piano wire) through the hole.
WARNING: Using a SST (piano wire) with bare hands can cause injury. Always wear gloves when using a SST (piano wire).
3. Wind each end of the SST (piano wire) around a bar.
4. Working with another person, saw through the sealant around the edge of the glass.
NOTE: Use a long sawing action to spread the work over the whole length of the SST (piano wire) to prevent it from breaking.
5. Remove the windshield.
6. Remove the dam from the windshield.
7. Remove the fasteners.
8. Remove spacers A and B.
WINDSHIELD 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 using a razor so that 1 - 2 mm {0.04 - 0.07 in} thickness 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 put on new sealant to create 2 mm {0.08 in} layer.
WARNING: Using a razor with bare hands can cause injury. Always wear gloves when using a razor.
2. Clean and degrease an approximately 50.0 mm {1.97 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 8.0 mm {0.31 in} from the edge.
4. Install the spacers B on the glass as shown.
5. Install spacers A into the hole.
6. Temporarily install the glass onto the body and adjust the glass-to-body clearance.
7. Make a mark on the glass directly above the V-notch of spacers A.
8. Verify that the gap along the upper edge is 7.3 mm {0.29 in}, and that the side edge is 6.8 mm {0.27 in}.
9. Remove the windshield.
10. Install the fasteners on the glass marks as shown.
11. Install the fasteners on the body as shown.
12. Use a brush to apply primer to the bonding area of the glass, the body, and the molding within the area shown.
CAUTION: Keep the area free of dirt and grease, and do not touch the surface, otherwise the primer may not properly bond to the surface of the glass and body, which may cause leaks to occur.
NOTE: Use only glass primer on the glass, and body primer on the body and the molding. Allow it to dry for approximately 30 minutes.
13. Once the primer is dry, apply sealant around the entire circumference to fill the gap between the dam and the edge of the glass measuring 11.0 mm {0.433 in} high and 5.0 mm {0.20 in} wide.
14. Align the glass marks with the V-notches in the spacers and install the glass onto the body.
15. Press firmly inward on the glass to compress the sealant.
16. Verify that the gap along the upper edge is 7.3 mm {0.29 in} and side edge is 6.8 mm {0.27 in}.
17. 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 it necessary.
Hardening Time Of Sealant:
18. Before the surface of the sealant has hardened, install the windshield molding.
19. Align the marking on the molding with the inner side of the body groove. (1)
20. Install the upper edge starting from the outer ends and moving inward. (2)
21. Install the corners. (3)
22. Install the windshield molding installation clips to the cowl grille hole. (4)
23. Install the sides, starting from the upper edge and moving downward, being careful not to pull out the corners. (5)
24. Use isopropyl alcohol to remove any excess sealant.
25. Install the headliner.
26. Install the cowl grille.
27. Install the base.
28. Install the rearview mirror.