Windshield: Service and Repair

Windshield Replacement

NOTE:

- Wear eye protection while cutting the glass adhesive with piano wire.
- Put on gloves to protect your hands.
- Use seat covers to avoid damaging any surfaces.
- Glass adhesive can be efficiently cut with a commercially available auto glass tool. See the tool manufacturer's instructions for details.

1. Remove these items:

- Rearview mirror Rearview Mirror Replacement
- A-pillar trims, both sides
- Windshield wiper arms Windshield Wiper Motor Replacement
- Windshield side trims, both sides Service and Repair
- Cowl covers Service and Repair

2. Remove the windshield molding (A) from the upper edge of the windshield (B). If necessary, cut the windshield molding with a utility knife.





3. If the original windshield will be reinstalled, make alignment marks across the windshield and the body with a grease pencil.

4. Pull down the front area of the headliner Service and Repair.

NOTE: Take care not to bend the headliner excessively, or you may crease or break it.

5. Apply protective tape along the edge of the dashboard and the body. Make a hole with an awl through the rubber dam, the adhesive, and dashboard seal from inside the vehicle at a corner of the windshield. Push a piece of piano wire through the hole, and wrap each end around a piece of wood.

6. With a helper on the outside, pull the piano wire (A) back and forth in a sawing motion. Hold the piano wire as close to the windshield (B) as possible to prevent damage to the body or the dashboard. Carefully cut through the rubber dam and adhesive (C) around the entire windshield.






Cutting positions





7. Carefully remove the windshield.

8. Scrape smooth the original adhesive with a knife until there is thickness of about 2 mm (0.08 in) on the bonding surface around the entire windshield opening flange:

- Do not scrape down to the painted surface of the body; damaged paint will interfere with proper bonding.
- Remove the rubber dam and the fasteners from the body.

9. Clean the body bonding surface with a shop towel dampened with isopropyl alcohol. After cleaning, keep oil, grease and water from getting on the clean surface.

10. If you are reinstalling the original windshield, scrape off all of the original adhesive, the rubber dams, and the dashboard seal from the windshield with a putty knife. Clean the bonding surfaces on the inside face and the edge of the windshield with isopropyl alcohol. Make sure the bonding surface is kept free of water, oil, and grease.

11. Apply glass primer to the upper clips mounting areas on the windshield (A), and let it dry. Remove the adhesive backing and attach the side rubber dams (B), the lower rubber dam (C), and the upper clips (D) to the windshield with adhesive tape. Attach the dashboard seal (E) to the inside of the windshield as shown:

- Make sure the side rubber dams, the lower rubber dam, and the dashboard seal line up with the alignment marks (F).
- Be careful not to touch the windshield where adhesive will be applied.





12. Apply glass primer to the edge of the windshield between the alignment marks (A). Be careful not to touch the windshield where adhesive will be applied.






13. Attach the windshield molding (A) with adhesive tape (B) to the edge of the windshield (C):

- Be sure the alignment mark (D) of the molding lines up with the alignment mark (E) of the windshield.
- Be careful not to touch the windshield where adhesive will be applied.





14. Attach the molding upper seal (A) to the inside surface of the windshield molding (B), and attach the non-woven fabric (C) as shown:

- Make sure the molding upper seal and non-woven fabric line up with the alignment dots (D).
- Be careful not to touch the windshield where adhesive will be applied.





15. Install the clips on the body.






16. Set the windshield in the opening, and center it. Make alignment marks (A) across the windshield and the body with a grease pencil at the four points shown. Be careful not to touch the windshield where adhesive is applied.





17. Remove the windshield.

18. Apply a light coat of glass primer to the windshield (A) along the edge of the side rubber dams (B), the lower rubber dam (C), and the windshield molding (D) as shown, then lightly wipe it off with gauze or cheesecloth:

- Apply glass primer to the molding.
- Do not apply body primer to the windshield, and do not mix up the body and glass primer applicators.
- Never touch the primed surfaces with your hands. If you do, the adhesive may not bond to the windshield properly, causing a leak after the windshield is installed.
- Keep water, dust, and abrasive materials away from the primed surface.





19. Carefully apply a light coat of body primer to any exposed paint around the windshield mounting flange where new adhesive is applied. Let the primer dry for at least 10 minutes:

- Do not apply body primer to any remaining original adhesive on the flange.
- Cover on the dashboard before applying the primer.
- Be careful not to mix up the body and glass primer applicators.
- Never touch the primed surfaces with your hands.





20. Cut a "V" in the end of the nozzle (A) on the adhesive cartridge as shown.






21. Put the cartridge in a caulking gun, and run a continuous bead of adhesive (A) around the edge of the windshield (B) between the side rubber dams (C), the lower rubber dam (D), and the windshield molding (E) as shown:

- Apply the adhesive within 30 minutes after applying the glass primer.
- Make a slightly thicker bead at each corner.





22. Hold the windshield with suction cups over the opening, align it with the alignment marks made in step 16, and set it down on the adhesive. Lightly push on the windshield until its edges are fully seated on the adhesive all the way around.

NOTE: Do not open or close any of the doors for about an hour until the adhesive is dry.

23. Remove the excess adhesive with a putty knife or a shop towel dampened with isopropyl alcohol.

24. Wait at least an hour for the adhesive to dry, then spray water over the windshield and check for leaks. Mark the leaking areas, let the windshield dry, then seal with sealant. Let the vehicle stand for at least 4 hours after windshield installation. If the vehicle has to be used within the first 4 hours, it must be driven slowly.

25. Reinstall all remaining removed parts.

NOTE: Advise the customer not to do the following things for 2 to 3 days:

- Slam the doors with all the windows rolled up.
- Twist the body excessively (such as when going in and out of driveways at an angle or driving over rough, uneven roads).