Page 1713 of 2893

(#'
) Cutting positions
20-38
Glass
Windshield Replacement
A
B A
B A
B
C
A B
A
A
A
C
A
NOTE:
Put on gloves to protect your hands.
Wear eye protection while cutting the glass adhesive with a piano wire.
Use seat covers to avoid damaging the seat.
When replacing a broken windshield, a commercially available windshield cutter can be efficiently used for
cutting the adhesive. For details, follow the tool
manufacturer’s instructions.
1. Remove these items: Windshield wiper arms (see page 22-233)
Cowl covers (see page 20-163)
Rearview mirror (see page 20-35)
A-pillar trim, both sides (see page 20-69)
Roof moldings (see page 20-165)
2. Remove the molding (A) from the upper edge of the windshield (B). If necessary, cut the molding with a
utility knife.
3. If the old windshield will be reinstalled, make alignment marks across the glass and the body
with a grease pencil.
4. Pull down the front portion of the headliner (see page 20-84). 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 and 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. 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 and the dashboard.
Carefully cut through the rubber dam and adhesive
(C) around the entire windshield.
7. Carefully remove the windshield.
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Page 1714 of 2893

Rubber dams adhesive tape:
Thickness 0.16 mm (0.006 in.)
Width 3.5 mm (0.14 in.)
Clips adhesive tape: Thickness 0.4 mm (0.016 in.)
Width 10 mm (0.39 in.)
20-39
Inside 11 mm
(0.43 in.)
B
D
12.3 mm
(0.48 in.) B
A
CE
E
E
AC B
D
12.3 mm
(0.48 in.)
12.8 mm
(0.5 in.) F
8. Scrape smooth the old adhesive, using a puttyknife or similar tool, until there is a 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 fasteners from the body.
Replace the dashboard seal with a new one.
9. 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.
10. If the old windshield will be reinstalled, scrape off the old adhesive, the fasteners, and the rubber dam
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. Attach the upper rubber dam (A), the lower rubber
dam (B), and the clips (C) with adhesive tape to the
inside face of the windshield (D) as shown:
Be sure the rubber dam and the clips line up with the alignment marks (E).
Be sure the convex portion (F) of the left and the right clips faces the left side.
Be careful not to touch the windshield where adhesive will be applied.
(cont’d)
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Page 1715 of 2893

Molding adhesive tape:
Thickness 0.8 mm (0.03 in.)
Width 4 mm (0.16 in.)
Seal adhesive tape: Thickness 0.16 mm (0.006 in.) Width 7 mm (0.28 in.) Rubber dam adhesive tape:
Thickness 0.16 mm (0.006 in.)
Width 5 mm (0.2 in.)
20-40Glass
Windshield Replacement (cont’d)
A
6mm
(0.24 in.)
B
C
C A
: Apply primer here. A
B
Inside
A
B A
A
B
A
12. Attach the molding (A) with adhesive tape (B) to the upper edge of the windshield (C). Be careful not to
touch the windshield where adhesive will be
applied.
13. Apply primer to the molding (A), then attach the molding upper seal (B) with adhesive tape to the
inside surface of the molding as shown. 14. Attach the lower rubber dam (A) with adhesive tape
to the body as shown.
Do not peel the glass side adhesive backing.
15. 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. Make sure both clips (B) contact with the
edge of the body holes. Be careful not to touch the
windshield where adhesive will be applied.
16. Remove the windshield.
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Page 1716 of 2893

20-41
: Apply glass primer here.
Inside
Inside
12 mm
(0.47 in.)
C
A
B
C
A B
A
B
B 16 mm
(0.63 in.)
16 mm
(0.63 in.)
16 mm
(0.63 in.) 5mm
(0.2 in.)
: Apply body primer to any exposed paint as shown.
12 mm (0.47 in.)
7 mm (0.28 in.)
A
17. Apply a light coat of glass primer with a sponge
applicator around the edge of the windshield (A)
between the dams (B) and molding (C) 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 get body and glass primer sponge
applicators 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 primed surfaces. 18. Carefully apply a light coat of body primer with a
sponge applicator to any exposed paint or metal
around the flange where new adhesive will be
applied. Let the primer dry for at least 10 minutes:
Do not apply body primer to any remaining original adhesive on the flange.
Be careful not to mix up the body and the glass primer sponge applicators.
Never touch the primed surfaces with your hands.
19. Cut a ‘‘V’’ in the end of the nozzle (A) on the adhesive cartridge as shown.
(cont’d)
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Page 1717 of 2893

20-42Glass
Windshield Replacement (cont’d)
12 mm (0.47 in.)
7 mm (0.28 in.)
2 mm (0.08 in.)
Inside Overlap
1mm(0.04in.)
C
A
D
A
B
C C A
B
D
2 mm (0.08 in.)
Inside
B
C
A
20. Put the cartridge in a caulking gun, and run a
continuous bead of adhesive (A) around the edge
of the windshield (B) between the dams (C) and the
molding (D) as shown. Apply the adhesive within
30 minutes after applying the glass primer. Make a
slightly thicker bead at each corner. 21. Pull out the glass side adhesive backing away from
the lower rubber dam.
22. Hold the windshield with suction cups over the opening, align it with the alignment marks made in
step 15, 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. Scrape or wipe the excess adhesive off with a putty knife or towel. To remove adhesive from a painted
surface or the windshield, wipe with a soft shop
towel dampened with isopropyl alcohol.
24. After the adhesive has dried, spray water over the windshield and check for leaks. Mark leaking area,
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).
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Page 1718 of 2893

(#'
)
20-43
Front Corner Glass Replacement
A B A
B
C
D
Fastener Locations
:Clip,2
A :Clip,2
B
A
B
NOTE:
Put on gloves to protect your hands.
Wear eye protection while cutting the glass adhesive.
Use seat covers to avoid damaging any surface.
1. Remove the A-pillar trim (see page 20-69).
2. From inside the vehicle, cut through the front corner glass adhesive (A) with a utility knife (B) all
the way around. Apply protective tape along the
edge of the entire front corner glass opening flange. 3. From outside the vehicle, pry the front corner glass
clips (A) and the front corner trim clips (B), then
carefully remove the glass (C) and the trim (D)
together. The trim is not attached to the glass.
4. Scrape smooth the old adhesive, using a putty knife or similar tool, until there is a thickness of
about 2 mm (0.08 in.) on the bonding surface
around the entire front corner glass opening flange:
Do not scrape down to the painted surface of the body; damaged paint will interfere with proper
bonding.
If any of the clips are broken, remove them from the body.
5. Clean the body bonding surface with a sponge applicator dampened in isopropyl alcohol. After
cleaning, keep oil, grease, and water from getting
on the surface.
6. If the old front corner glass will be reinstalled, scrape off the old adhesive with a putty knife from
the front corner glass. Clean the bonding surfaces
on the inside face of the front corner glass and the
edge of the glass with isopropyl alcohol. Make sure
the bonding surface is kept free of water, oil and
grease.
(cont’d)
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Page 1719 of 2893

Rubber dam adhesive tape:
Thickness 0.16 mm (0.006 in.)
Width 3 mm (0.12 in.)
Clip adhesive tape: Thickness 1.2 mm (0.047 in.)
Width 9 mm (0.35 in.)
20-44Glass
Front Corner Glass Replacement (cont’d)
33.5 mm
(1.32 in.)
Inside
A C A
BC
19 mm
(0.75 in.)
10 mm
(0.39 in.)
B
B
C
A
15.5 mm
(0.61 in.)
3mm
(0.12 in.)
A
B
C : Apply glass primer here.
Inside 6.5 mm
(0.26 in.)
11 mm
(0.43 in.)
5.5 mm
(0.22 in.)5.5 mm
(0.22 in.)
A
A
A
A B
11 mm
(0.43 in.) 11 mm
(0.43 in.)
A Inside
7mm
(0.28 in.)
Inside
7. Attach the rubber dam (A) and the clips (B) with
adhesive tape to the inside face of the front corner
glass (C) as shown.
Be careful not to touch the front corner glass where
adhesive will be applied. 8. Apply a light coat of glass primer with a sponge
applicator to the inside face of the front corner
glass (A) as shown, then lightly wipe it off with
gauze or cheesecloth:
With the printed dots (B) on the front corner glass as a guide, apply the glass primer to both lower
corner portions of the front corner glass.
Do not apply body primer to the front corner glass, and do not get body and glass primer
sponge applicators mixed up.
Never touch the primed surfaces with your hands. If you do, the adhesive may not bond to the front
corner glass properly, causing a leak after the
front corner glass is installed.
Keep water, dust, and abrasive materials away from primed surfaces.
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Page 1720 of 2893

20-45
: Apply body primer here.
16 mm
(0.63 in.)
5mm
(0.2 in.)
5mm
(0.2 in.)
16 mm
(0.63 in.) 16 mm
(0.63 in.)
10 mm (0.39 in.)
7mm(0.28in.)
A Inside
10 mm
(0.39 in.)
A
B
7mm
(0.28 in.)
AA
B C
A
B
8.5 mm
(0.33 in.) 2mm
(0.08 in.)2mm
(0.08 in.)
A B A
B
Inside
Inside
2mm
(0.08 in.)
9mm
(0.35 in.)
9. Carefully apply a light coat of body primer with asponge applicator to any exposed paint or metal
around the flange where new adhesive will be
applied. Let the primer dry for at least 10 minutes:
Do not apply body primer to any remaining original adhesive on the flange.
Be careful not to mix up the body and glass primer sponge applicators.
Never touch the primed surfaces with your hands.
Mask off the dashboard before painting the flange.
10. Cut a ‘‘V’’ in the end of the nozzle (A) on the adhesive cartridge as shown. 11. Put the cartridge in a caulking gun, and run a
continuous bead of adhesive (A) around the front
corner glass (B) as shown:
With the printed dots (C) on the front corner glass as a guide, apply the adhesive to both side
portions of the front corner glass.
Apply the adhesive within 30 minutes after applying the glass primer. Make a slightly thicker
bead at each corner.
(cont’d)
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