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Windshield: Service and Repair

Windshield Replacement

CAUTION:
- Put on gloves to protect your hands.
- Use seat covers to avoid damaging any surfaces.

1. To remove the windshield, first remove the:
- Rearview mirror
- Sunvisors and holders
- Ceiling light
- Grab handle
- Front door trim
- Front pillar trim
- Windshield wiper arms and cowl cover




2. Remove the molding and glass brackets.

NOTE: If removing the molding is difficult, cut the molding with a utility knife.

3. Pull down the front portion of the headliner.

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




4. Apply protective tape along the edge of the dashboard and body as shown. Using an awl, make a hole through the rubber dam and adhesive from inside the vehicle. Push a piece of piano wire through the hole, and wrap each end around a piece of wood.

CAUTION: Hold the piano wire as close to the windshield as possible to prevent damage to the body and dashboard.




5. With a helper on the outside, pull the piano wire back and forth in a sawing motion, and carefully cut through the rubber dams and adhesive around the entire windshield.
6. Carefully remove the windshield.
7. Using a knife, scrape the old adhesive smooth to a thickness of about 2 mm (0.08 in.) on the bonding surface around the entire windshield opening flange.

NOTE:
- Do not scrape down to the painted surface of the body; damaged paint will interfere with proper bonding.
- Remove the rubber dams and fasteners from the body.
- Mask off surrounding surfaces before painting.

8. Clean the body bonding surface with a sponge dampened in alcohol.

NOTE: After cleaning, keep oil, grease and water from getting on the surface.




9. If the old windshield is to be reinstalled, use a putty knife to scrape off all traces of old adhesive and the rubber dams, then clean the windshield surface with alcohol where new adhesive is to be applied.

NOTE: Make sure the bonding surface is kept free of water, oil and grease.

CAUTION: Avoid setting the windshield on its edges; small chips may later develop into cracks.

NOTE: Clean the shadowed area.




10. Glue the rubber dams and fasteners to the inside face of the windshield as shown.

NOTE: Be careful not to touch the windshield where adhesive will be applied.




11. Glue the molding side seal and molding upper seal to the molding on each side.




12. Align and glue the molding to the edge of the windshield.

NOTE: Be careful not to touch the windshield where adhesive will be applied.

a. With a brush, apply a light coat of primer (3M N-200, or equivalent) to the edge of the windshield as shown,
b. Glue the adhesive tapes (3M 4212, or equivalent) to both bottom edges of the windshield.
c. Align the alignment mark on the molding to the alignment mark of the windshield.
d. Glue the molding to the edge of the windshield.




13. Install the glass brackets and fasteners to the body as shown.




14. Set the windshield on the glass brackets, then center it in the opening. Make alignment marks across the windshield and body with a grease pencil at the four points shown.

NOTE: Be careful not to touch the windshield where adhesive will be applied.

15. Remove the windshield.




16. With a sponge, apply a light coat of glass primer around the edge of the windshield as shown, then lightly wipe it off with gauze or cheesecloth.

NOTE:
- Do not apply body primer to the windshield, and do not get body and glass primer sponges mixed up.
- 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.




17. With a sponge, apply a light coat of body primer to the original adhesive remaining around the windshield opening flange. Let the body primer dry for at least 10 minutes.

NOTE:
- Do not apply glass primer to the body, and be careful not to mix up glass and body primer sponges.
- Never touch the primed surfaces with your hands.
- Mask off the dashboard before painting the flange.




18. Before filling a cartridge, cut the end of the nozzle as shown.




19. Pack adhesive into the cartridge without air pockets to ensure continuous delivery. Put the cartridge in a caulking gun, and run a bead of adhesive around the edge of the windshield as shown.

NOTE: Apply the adhesive within 30 minutes after applying the glass primer.




20. Use suction cups to hold the windshield over the opening, align it with the alignment marks made in step 14, and set it down on the adhesive. Lightly push on the windshield until its edge is fully seated on the adhesive all the way around.

NOTE: Do not open or close the doors until adhesive is dry.

21. Scrape or wipe the excess adhesive off with a putty knife or towel.

NOTE: To remove adhesive from a painted surface or the windshield, wipe with a soft shop towel dampened with alcohol.

22. Let the adhesive dry for at least 1 hour, then spray water over the windshield and check for leaks. Mark leaking areas, and let the windshield dry, then seal with sealant.

NOTE:
- 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.
- Keep the windshield dry for the first hour after installation.
- Check that the ends of the side molding are set under the cowl cover.

23. Reinstall all remaining removed parts.

NOTE:
- Install the rearview mirror rubber damper after the adhesive has dried thoroughly.
- 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).
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