Remove the windshield molding (A) from the upper edge of the windshield (B). If necessary, cut off the molding with a utility knife.
2.
If the original windshield will be reinstalled, make alignment marks across the windshield and the body with a grease pencil.
Cutting positions
3.
Apply protective tape along the edge of the dashboard and the body. Make a hole with an awl or similar tool through the rubber dam and the adhesive 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.
4.
With an assistant 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.
5.
Carefully remove the windshield.
6.
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 putty knife.
NOTE:
Do not scrape down to the painted surface of the body; damaged paint will interfere with proper bonding.
Remove the rubber dam from the body.
7.
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.
8.
If you are reinstalling the original windshield, scrape off all of the original adhesive, the clips, the rubber dam, 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.
Install the new clips (A) with the adhesive tape on the inside face of the windshield (B) as shown.
NOTE:
Before installing the clips, apply 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 clips and the rubber dam line up with the alignment marks (C).
2.
Install the new rubber dam (D) with adhesive tape to the windshield (E) as shown.
NOTE:
Be careful not to touch the windshield where the adhesive will be applied.
Make sure the rubber dam line up with the alignment marks (F).
3.
Cut the rubber dam to the length, then install the new rubber dams (A, B, C, D).
Rubber dam length:
Rubber dam A:
210 mm (8.27 in)
Rubber dam B:
816 mm (32.13 in)
Rubber dam C:
27 mm (1.06 in)
Rubber dam D:
46 mm (1.81 in)
4.
Install the new windshield upper molding (A) and the new windshield lower molding (B) with adhesive tape to the windshield (C) as shown.
NOTE:
Be careful not to touch the windshield where the adhesive will be applied.
Make sure the windshield upper molding contact with the edge of the windshield.
Make sure the windshield lower molding contact with the edge of the windshield.
5.
Set the windshield (A) 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 upper clips (C) contact with the edge of the body holes.
6.
Remove the windshield.
7.
Apply a light coat of primer to the windshield (A) along the edge of the windshield upper molding (B) and the rubber dam (C) as shown, then lightly wipe it off with gauze or cheesecloth.
NOTE:
Apply the primer to corner areas of the windshield using the printed dots (D) on the windshield as a guide.
Apply 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 primed surfaces.
8.
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 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.
9.
Cut a ‘‘V’’ at the end of the adhesive cartridge nozzle (A) as shown.
10.
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 dam (D) as shown.
NOTE:
Apply the adhesive within 30 minutes after applying the primer.
Apply the adhesive to the using the printed dots (E) on the windshield as a guide.
Make a slightly thicker bead at each corner.
11.
Hold the windshield with suction cups over the opening, align it with the alignment marks made in step 5, 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.
12.
Remove the excess adhesive with a putty knife or a shop towel dampened with isopropyl alcohol.
13.
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.
14.
Advise the customer 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).
