Windshield: Service and Repair
WINDSHIELD - COUPEREMOVAL
CAUTION:
- ALWAYS WEAR HEAVY GLOVES AND SAFETY GLASSES WHEN HANDLING GLASS TO MINIMIZE THE RISK OF INJURY.
- 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.
NOTE: Place protective covers on body to prevent paint damage.
1. Remove roof outer drip rail.
2. Remove antenna mast.
3. Remove wiper arm assemblies.
4. Remove shroud top vent grille and disconnect windshield washer hose.
5. Remove rearview mirror.
6. Remove instrument panel-top cover.
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.
IMPORTANT: The seal on the forward edge of the instrument panel is not trapped between the windshield and spaceframe. If so, remove the seal and place on forward edge of the instrument panel - upper trim panel.
7. Remove windshield garnish moldings.
8. Remove sunshades and sunshade supports.
9. If equipped, remove roof front compartment bezel.
10. Remove right front assist strap fastener cover by prying gently between headliner and cover on outboard side. Once the cover unsnaps from clip, push cover inward. Remove fasteners and remove assist strap.
11. Lower front half of headliner. Use lightweight wood or foam block to hold headliner down.
CAUTION: WHEN USING POWER TOOLS THAT MAY CREATE SMOKE WHEN CUTTING URETHANE SEALANT, WORK SHOULD BE DONE IN A WELL VENTILATED AREA AND/OR WITH A NIOSH/MSHA APPROVED AIR SUPPLIED RESPIRATOR TO PREVENT POSSIBLE HARMFUL EXPOSURE.
WHEN THE URETHANE ADHESIVE IS HEATED ENOUGH TO GIVE OFF SMOKE, HIGH LEVELS OF METHYLENE DI-ISOCYANATE (MDI) MAY BE PRESENT.
UNPROTECTED EXPOSURE TO METHYLENE DI-ISOCYANATE (MDI) MAY RESULT IN SEVER CHRONIC, DEBILITATING RESPIRATORY PROBLEMS.
NOTE: Care must be taken not to damage the roof when using power glass removal tool. If necessary, tape off body around glass with thick tape.
12. Using a power glass removal tool, cut urethane seal along roof from inside vehicle and bottom and sides from outside vehicle. Open hood to gain access to bottom.
1. Cut from inside of vehicle
2. Cut from outside of vehicle
3. Windshield stops
4. Cut with piano wire
The bottom comers of the windshield urethane seal will need to be cut using piano wire in areas as shown in illustration.
13. With the aid of a helper, remove glass.
INSTALLATION
IMPORTANT: Loose urethane and/or a rough surface on remaining urethane may cause sealing problems during installation.
1. Remove old urethane with a razor knife leaving a thin film (approximately 1-2 mm [0.04-0.08 in.]) around the perimeter of window opening and windshield (if being reused).
2. Clean the entire window opening and glass bonding surfaces with a clean, lint free, alcohol dampened cloth. Allow to air dry.
NOTE: 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 manufacturer's recommendations for drying time.
3. New windshield only - Shake glass prep primer (Clear #1) well before applying. Apply glass prep primer (Clear #1) around the entire perimeter of glass using dauber. Wipe dry with a clean lint-free cloth.
Primer area (Minimum Width, A): 18 mm (0.71 in.)
Shake glass primer (Black #2) well before applying. With a new dauber apply glass primer around the entire perimeter over Clear #1. Allow primer to dry five minutes.
Primer area (Minimum Width, A): 18 mm (0.71 in.)
4. Apply a smooth continuous bead of adhesive directly to old urethane adhesive in glass opening or to glass. Apply according to dimensions shown.
Bead Dimension
Minimum Width - B: 8 mm (0.32 in.)
Minimum Height - C: 13 mm (0.51 in.)
Use primer line along top of replacement glass as a guide when applying adhesive to glass.
5. With aid of a helper, lift glass into window opening. Align glass assembly to notches in roof panel.
6. Press glass firmly to wet-out and set adhesive. Use care to avoid excessive squeeze out which would cause an appearance problem. Using duct tape or equivalent tape glass up to roof.
NOTE: Until the new urethane has cured, air pressure from a closing door may cause the windshield to move. To prevent this, lower the rear seat and open the decklid before closing the door.
IMPORTANT: Vehicle must remain at normal room temperature for 6 hours to complete proper cure of adhesive. Refer to manufacturer's recommendation.
7. Watertest vehicle at once using soft spray. Use warm or hot water if available. Do not direct hard stream of water at fresh adhesive material. Water applied on top of urethane adhesive, during watertest or as a separate operation, will speed up the cure of the urethane.
8. Inspect for leaks from inside the vehicle. Paddle in extra adhesive at leak points using a tongue depressor or similar flat flexible tool.
9. Remove blocks used to hold headliner down.
10. Install windshield garnish molding.
11. If equipped, install roof front compartment bezel.
12. Install right front assist strap.
13. Install sunshades and sunshade supports.
14. Install instrument panel top cover.
15. Install rearview mirror.
16. Install shroud top vent grille. Connect windshield washer hose.
17. Install wiper arm assemblies.
18. Install antenna mast.
19. Install roof outer drip rail.