Windshield Glass

Special Tool(s)

	Deluxe Windshield Removal Tool 164-R2450 or equivalent
	The Pumper 164-R2459 or equivalent

Removal

1. Remove the exterior A-pillar window mouldings. For additional information, refer to Section 501-08 .

2. Remove the cowl panel grille upper and the cowl panel grille side mouldings. For additional information, refer to Cowl Panel Grille in Section 501-02 .

3. Remove the interior A-pillar trim panels. For additional information, refer to Section 501-05 .

4. Remove the interior rear view mirror. For additional information, refer to Section 501-09 .

5. Remove the overhead console. For additional information, refer to Section 501-12 .

6. Remove the passenger front assist handle.

7. Remove the LH and RH sun visors and clips.

8. Lower the front portion of the headliner and block with a suitable material.

9.  WARNING: Wear eye and ear protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury.

    WARNING: Wear protective gloves when handling components or parts that have pointed or sharp edges. Failure to follow this instruction may result in serious personal injury.

   NOTE: Lubricate the existing urethane adhesive with water to aid the Deluxe Windshield Removal Tool while cutting.

   Working from inside the vehicle, using the deluxe windshield removal tool, cut the urethane adhesive starting at the top center and working toward the bottom corners then across the bottom.

10. Using The Pumper, distance the windshield glass from the body.

11. Using the Deluxe Windshield Removal Tool, cut the remaining urethane adhesive and remove the windshield glass.

Installation

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 (if equipped) and the body to aid in the installation alignment of the windshield glass.

3. Remove the windshield glass and place on a stable surface.

4.  WARNING: Repair any corrosion found on the pinch weld. The pinch weld is a structural component of the vehicle. Corrosion left unrepaired may reduce the structural integrity of the vehicle. Failure to follow this instruction may result in serious injury to vehicle occupant(s).

   NOTE: Avoid scratching the pinch weld. Repair all minor scratches or exposed metal on the pinch weld following manufacturer's instructions. Use the same brand pinch weld primer, glass primer and urethane adhesive.

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

5. Using a soft brush or vacuum, remove any dirt or foreign material from the pinch weld.

6. If installing the original windshield glass, remove the excess urethane adhesive.

7. Clean the inside of the windshield glass surface with glass cleaner.

8. NOTE: Be sure to use the same brand and cure-rate products for the urethane adhesive and glass primer. Do not mix different brands of urethane adhesive and glass primer. For additional information, refer to the Material Chart in this procedure.

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

9. Cut the urethane adhesive applicator tip to specification.

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

    Apply urethane adhesive on top of the existing trimmed urethane adhesive bead on the pinch weld, starting and ending at the bottom of the windshield near the center, making sure there are no gaps in the bead.

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

12.  WARNING: Improper curing of the urethane adhesive may adversely affect glass retention, which is important for restraint system performance during a crash. Carefully follow the urethane adhesive manufacturer's curing instructions. Do not drive the vehicle until the urethane adhesive seal has cured. Failure to follow these instructions may result in serious injury to vehicle occupant(s) during a crash.

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

13. Position the front portion of the headliner.

14. Install the LH and RH sun visors and clips.

15. Install the passenger front assist handle.

16. Install the overhead console. For additional information, refer to Section 501-12 .

17. Install the interior rear view mirror. For additional information, refer to Section 501-09 .

18. Install the A-pillar trim panels. For additional information, refer to Section 501-05 .

19. Install the cowl panel grille upper and the cowl panel grille side mouldings. For additional information, refer to Section 501-02 .

20. Install the exterior A-pillar window mouldings. For additional information, refer to Section 501-08 .

21. Clean the interior and exterior windshield glass with glass cleaner.