Windshield Replacement
Windshield Replacement
Removal Procedure
Caution: Always wear heavy gloves and safety glasses when handling glass to minimize the risk of injury.
Notice: Place protective covers on body to prevent paint damage.
1. Remove the rear weather-stripping from the cowl area.
2 Remove the windshield wiper arm nut cap.
3. Remove the windshield wiper arm nut.
4. Remove the lower windshield molding to provide access to remove the air inlet grill panel.
5. Remove the air inlet grill.
6. Remove the A pillar weather-stripping and discard.
7. Remove the windshield A pillar moldings by firmly pulling out and rocking them back and forth to unsnap the clips.
8. Remove the upper windshield to roof molding by pulling from one side to another and discard.
9. Remove the rearview mirror by loosening the screw.
Caution: If broken glass falls into defroster outlets, it can be blown into the passenger compartment and cause injuries. To help avoid personal injury, cover the defroster outlets before replacing windows.
10. Cover the instrument panel upper dash panel and defroster ducts with a blanket or cloth.
11. Install the duct tape along the roof to protect it from the cutting tool during windshield removal.
12. Using the power glass removal tool, cut the urethane seal along the roof's A pillars and the front of the dash.
13. With the aid of a helper, remove the glass.
Installation Procedure
Important: Loose urethane and/or a rough surface on the remaining urethane may cause sealing problems during installation.
1. Clean the old sealer from the body pinch weld area using a razor or knife. Leave a thin film, approximately 1-2 mm (0.04-0.08 in), around the perimeter of the window opening and the windshield, if being reused.
2. Clean the entire window opening and the glass bonding surfaces with a clean, lint-free, alcohol dampened cloth.
Notice: To prevent corrosion, paint damage around the window opening by the power glass removal tool must be covered with pinchweld primer. Do not prime over existing urethane. Follow manufacturers recommendations for drying time.
Important: Shake glass prep primer, Clear #1, well before applying.
3. On a new windshield only, apply the glass prep primer, Clear #1, around the entire perimeter of the glass using a dauber. Wipe dry with a clean, lint-free cloth.
The primer area minimum width for A is 18 mm (0.71 in).
Important: Shake the glass primer, Black #2, well before applying.
4. With a new dauber, apply the glass prep primer, Black #2, around the entire perimeter over Clear #1. Allow the primer to dry 5 minutes before applying the urethane.
The primer area minimum width for A is 18 mm (0.71 in).
5. Install the upper windshield molding.
6. Install both lower windshield moldings.
7. Test fit the windshield and install the tape in 4 locations around the windshield and body.
8. Draw the alignment marks on the tape to assist in the alignment during installation.
9. Install the air inlet grill panel and nuts.
Tighten the air inlet grill panel nuts to 1 N.m (9 lb in).
10. Remove the windshield.
11. Apply a smooth bead of urethane directly to the old urethane adhesive in the pinchwield area on the body of the glass. Apply according to the dimensions below:
* The bead dimension width B is 8 mm (0.31 in).
* The bead dimension height C is 14 mm (0.55 in).
12. With the aid of a helper, lift the glass into the window opening and align with the previously made marks on the windshield and the body. Make certain that the lip of the applied molding laps over the roof feature line.
13. Adjust the windshield using the cams on the front of the dash.
14. Press firmly to wet-out and set the adhesive. Use care to avoid excessive squeeze-out which would cause an appearance problem.
Notice: Until the new urethane has cured, air pressure from a closing door may cause the glass to move. To prevent this, lower the opposite side door window a minimum of 76 mm (3 in) before closing the door.
15. Apply the tape from the windshield to the roof panel to hold in position until the urethane adhesive has cured.
16. Water test the vehicle at once using a soft spray. Use warm water if available. Do not direct a hard stream of water on the fresh adhesive material. Water applied on top of the urethane adhesive, either during water test or as part of a separate operation, will speed up the cure of the adhesive.
17. Inspect for leaks from the inside of the vehicle. Paddle in extra adhesive at leak points using a tongue depressor or similar flat, flexible tool.
18. Install the windshield A pillar moldings and snap into place.
19. Orient the weather-strip, as shown in the figure, in such a way that the short lip on the weather-stripping rests on A pillar and the long lip rests on the windshield.
20. Install the rearview mirror; then slide it down toward the dash and tighten the screw.
Tighten the rear view mirror screw to 4 N.m (35 lb in).
21. Install the rear hood weather-strip.
22. Install the windshield wiper arm, washer, and nut.
Tighten the windshield wiper arm nut to 12 N.m (9 lb ft).
23. Install the wiper arm nut cap.
Important: The vehicle must remain at normal room temperature for 6 hours to complete the proper cure of the adhesive. Refer to the manufacturer's recommendation.
24. Remove the blanket or cloth carefully from the instrument panel upper dash panel and defroster ducts.