Windshield: Service and Repair
WINDSHIELD - SEDAN/WAGONREMOVAL
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 air inlet grille.
2. Remove windshield pillar lower side applique.
3. Remove roof side outer front panel.
4. Remove rearview mirror.
5. Remove instrument panel - top cover.
6. Partially remove windshield garnish molding around windshield opening.
7. Remove sunshades and sunshade supports.
8. If equipped, remove roof front compartment bezel.
9. 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 SEVERE, 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.
10. Using a power glass removal tool, cut urethane seal along roof from inside vehicle and bottom from outside vehicle. Open hood to gain access to bottom.
11. The bottom corners and sides of the windshield urethane seal will need to be cut using piano wire.
12. 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) 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 manufacturers 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 prep primer (Black #2) around the entire perimeter over (Clear #1). Allow primer to dry five minutes before applying urethane.
Primer area (Minimum Width, A): 18 mm (0.71 in.)
4. Apply a smooth continuous bead of urethane adhesive over black prime.
Bead Dimension
Minimum Width - B: 10 mm (0.39 in.)
Minimum Height - C: 14 mm (0.55 in.)
5. With aid of a helper, lift glass into window opening. Align top edge of glass with notches in roof panel. Make certain the lip of the applied molding laps over roof feature line.
6. Press glass firmly to wet-out and set adhesive. Use care to avoid excessive squeeze out which would cause an appearance problem. Use tape from windshield to roof panel to hold in position until urethane adhesive is cured.
NOTE: Until the urethane has cured, air pressure from a closing door may cause the windshield to move. To prevent this, lower one of the rear door windows a minimum of 76 mm (3 in.) 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 the vehicle at once using a soft spray. Use warm or hot water if available. Do not direct a hard stream of water on fresh adhesive material. Water applied on top of urethane adhesive, either during watertest or part of a separate operation, will speed up the cure of 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. If equipped, install roof front compartment bezel.
11. Install sunshades and sunshade supports.
12. Install windshield garnish molding.
13. Install instrument panel - top cover.
14. Install rear view mirror.
15. Install air inlet grille.
16. Install roof side outer front panel. Tighten fasteners in sequence shown.
Torque:
Roof Side Outer Front Panel Fasteners: 1.5 N.m (13 in.lbs)
17. Install windshield pillar lower side applique.