Remove the windshield upper molding (A) from the upper edge of the windshield (B). If necessary, cut the windshield upper molding with a utility knife.
2.
With heated windshield wiper area: Disconnect the connector (C), and remove the connector clip (D).
NOTE: If you are reusing the windshield you are removing, note the routing of the harness (Type 1 or 2) before removing the connector clip.
3.
If the original windshield will be reinstalled, make alignment marks (A) across the glass and the body with a grease pencil.
Cutting positions
4.
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 the dashboard seal from inside of the vehicle at a corner portion of the windshield. Push a piece of piano wire through the hole, and wrap each end around a piece of wood.
5.
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 and the dashboard. Carefully cut through the rubber dam and the adhesive (C) around the entire windshield.
6.
Carefully remove the windshield.
7.
Scrape the original adhesive smooth to a thickness of about 1 mm (0.04 in) - 2 mm (0.08 in) on the bonding surface around the entire windshield opening flange with a knife:
NOTE:
Do not scrape down to the painted surface of the body; damaged paint will interfere with proper bonding.
Remove the rubber dams, the dashboard seal, and the fasteners from the body.
8.
Clean the body bonding surface with a shop towel dampened in isopropyl alcohol. After cleaning, keep oil, grease, and water from getting on the clean surface.
9.
If you are reinstalling the original windshield, scrape off all of the original adhesive, the clips, the dashboard seal, and the rubber dam from the windshield with a putty knife. Clean the boning surface 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.
Install the new windshield upper molding (A), the clips (B) with the adhesive tape on the inside face of the windshield (C) as shown.
2.
Cut the rubber dam to the length, then install the new lower seal (D).
Lower seal length:
Lower seal :
1345 mm (52.95 in)
NOTE:
Before installing the new windshield upper molding, apply a glass primer to the area where the adhesive tape will be applied.
Be careful not to touch the windshield where the adhesive will be applied.
Make sure the index tabs (E) on the clips face the right side.
Make sure the clips and the lower seal line up with the alignment marks (F).
3.
Cut the rubber dam to the length, then install the new side rubber dams (A) and the new lower rubber dam (B).
Rubber dam length:
Side rubber dam A:
970 mm (38.19 in)
Lower rubber dam B:
1076 mm (42.36 in)
NOTE:
Be careful not to touch the windshield (C) where the adhesive will be applied.
Make sure the lower seal line up with the alignment marks (D).
4.
If you are installing the new windshield (A), set the windshield in the opening, and center it. Make the alignment marks (B) across the windshield and the body with a grease pencil at the four points shown.
NOTE:
Be careful not to touch the windshield where the adhesive will be applied.
Make sure the clips (C) contact with the edge of the body holes.
5.
Remove the windshield.
6.
Apply a light coat of primer to the windshield (A) along the edge of the rubber dams (B) and the windshield upper molding (C) as shown, then lightly wipe it off with gauze or cheesecloth.
NOTE:
Apply the primer to the corner areas (D) using the printed lines (E) on the windshield as a guide.
Do not apply the 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 primed surfaces.
7.
Apply a light coat of the body primer to any exposed paint or metal on the windshield mounting flange. Let the body primer dry for at least 10 minutes.
NOTE:
Do not apply the glass primer to the body.
Do not apply the body primer to any remaining original adhesive on the flange.
Cover on the dashboard before applying the body primer.
Be careful not to mix up the body and glass primer applicators.
Never touch the primed surfaces with your hands.
8.
Cut a ‘‘V’’ in the end of the nozzle (A) on the adhesive cartridge as shown.
9.
Put the cartridge in a caulking gun, and run a continuous bead of adhesive (A) on the windshield (B) along the edge of the windshield upper molding (C) and the rubber dams (D) as shown.
NOTE:
Apply the adhesive to the corner areas (E) using the printed line (F) on the windshield as a guide.
Apply the adhesive within 30 minutes after applying the glass primer.
Make a slightly thicker bead at each corner.
10.
Hold the windshield with the suction cups over the opening, align it with the alignment marks made in step 2, 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. Carefully remove the suction cups.
NOTE: Do not open or close any of the doors for about an hour until the adhesive is dry.
11.
Remove the excess adhesive with a putty knife or a shop towel dampened with isopropyl alcohol.
12.
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.
13.
Advise the client not to do the following things for 2 to 3 days:
Do not slam the doors with all the windows rolled up.
Do not twist the body excessively (such as when going in and out of driveways at an angle or driving over rough, uneven roads).
14.
With heated windshield wiper area: Install the connector clip (A) as shown.
NOTE: If you are reusing the windshield you removed, route the harness as it was removed. If you are replacing the windshield, route the harness to a type 2 as shown.
