Removal and Replacement

WINDSHIELD GLASS

Special Tool(s):

Special Tool(s)

Material:

Material







Removal

1. WARNING: To prevent glass splinters from entering the eyes or cutting the hands, wear safety glasses and heavy gloves when cutting the glass from the vehicle. Failure to follow these instructions may result in personal injury.

Remove the cowl panel grilles.

2. Remove the A-pillar trim panels.
3. If equipped, remove the overhead console.
4. If equipped, remove the interior lamp.
- Disconnect the electrical connectors.

5. Remove the interior mirror.
6. Remove the 4 screws and the LH and RH sun visors.







7. Remove the LH and RH sun visor retaining clips.
1 Open the covers.
2 Remove the screws.

8. Partially lower the headliner and place 2 blocks of suitable material between the headliner and the roof opening to act as spacers.







9. CAUTION: Make sure the cutting blades are changed where the cutting depth changes to avoid damage to the body and trim panels.

NOTE:
- Some resistance may be encountered when cutting through the glass locating pegs in the lower corners of the glass.
- Lubricate the urethane adhesive with water to aid the special tool when cutting the urethane adhesive. Using the special tool, place the flat side of the knife against the rear glass. Start at the top center and work out and down the pillars to the lower corners to the given maximum depths:

1 23 mm (0.9 in)
2 75 mm (2.95 in)
3 160 mm (6.29 in)







10. Install the special tool into the top of the windshield glass and inflate. Cut the urethane adhesive from corner to corner along the bottom of the windshield glass.
11. Remove the windshield glass and the windshield weatherstrip.
12. Using a soft brush or vacuum, remove any dirt or foreign material from the pinch weld.
13. Remove the remaining part of the glass locating pegs from the windshield glass flange.

Installation

CAUTION: When installing urethane-installed glass parts, the vehicle must not be driven until the urethane has cured. Adequate cure time is specified on the drive away chart for each urethane product as the temperatures and humidity vary. Inadequate or incorrect curing can adversely affect the retention of the windshield.

NOTE: For additional material guidelines, refer to the manufacturer's installation information.

1. Dry fit the windshield glass to the existing urethane adhesive bead on the body pinch weld. Align the windshield glass in the opening for a uniform fit.
2. Use a non-permanent pencil to make alignment marks on the windshield glass at the setting blocks and the body to aid in the installation alignment of the windshield glass.
3. Remove the windshield glass.







4. NOTE: Avoid scratching the pinch weld. For minor scratches or exposed metal on the pinch weld, see the manufacturer's recommendations.

Using an appropriate tool, trim the urethane adhesive leaving a 1-2 mm (0.04-0.08 in) base of original equipment urethane on the pinch weld.

5. If installing the original windshield glass, remove the excess urethane adhesive.
6. Clean the inside of the windshield glass surface with glass cleaner.

7. CAUTION: Be sure to use the same brand of cure-rate products for the adhesive and primer. Do not mix different brands of urethane and primer. Refer to the Material Chart in this procedure.

NOTE: Sika uses the same black primer for the glass and pinch weld area.

If installing a new windshield glass, apply urethane glass primer according to the manufacturer's instructions. Allow at least 6 minutes to dry.







8. Cut the urethane adhesive applicator tip to the specification.







9. NOTE: Use either a high-ratio, electric or battery-operated caulk gun that will apply the urethane with less effort and a continuous bead.

Apply urethane adhesive on top of the existing trimmed urethane adhesive bead on the pinch weld. Make sure that all gaps in the urethane adhesive are smoothed into one continuous bead starting and ending at the bottom of the windshield near the center.

10. Install the windshield glass weatherstrip.
11. Install the windshield glass on the vehicle aligning it with the markings made previously.

12. CAUTION: When installing urethane-installed glass parts, the vehicle must not be driven until the urethane has cured. Adequate cure time is specified on the drive away chart for each urethane product as the temperatures and humidity vary. Inadequate or incorrect curing can adversely affect the retention of the windshield.

After the urethane has cured, check the windshield glass seal for air or water leaks through the urethane adhesive bead and add urethane adhesive as necessary.

13. Remove the spacers and attach the headliner to the roof panel.







14. Install the sun visor retaining clips.
1 Install the screws.
2 Close the covers.

15. Install the LH and RH sun visors and the 4 screws.
16. Install the interior mirror.
17. If equipped, connect the electrical connectors and install the interior lamp.
18. If equipped, install the overhead console.
19. Install the A-pillar trim panels.
20. Install the cowl panel grilles.