Windshield Replacement
Note. Put on gloves to protect your hands. Wear eye protection when removing the glass with piano wire. Use seat covers to avoid damaging the seat. Glass adhesive can be efficiently cut with a commercially available auto glass tool. See the tool manufacturer's instructions for details.
Scheme 22
Scheme 23
Scheme 24
Scheme 25
Scheme 26
Scheme 27
Scheme 28
Scheme 29
Scheme 30
Scheme 31
Scheme 32
Scheme 33
- Remove these items: Rearview mirror (see «REARVIEW MIRROR REPLACEMENT»(ref-371407-S03777632772010091000000) ) Side windshield trims, both sides (see «SIDE WINDSHIELD TRIM REPLACEMENT»(ref-371384-S25877262922010091000000) ) Windshield wiper arms (see «WIPER MOTOR REPLACEMENT»(ref-371411-S22023082092010091000000) ) Cowl covers (see «COWL COVER REPLACEMENT»(ref-371384-S16589117572010091000000) )
- Remove the molding (A) from the upper edge of the windshield (B). If necessary, cut the molding with a utility knife. (Scheme 22): Locating Molding And Windshield
- If the old windshield is to be reinstalled, make alignment marks (A) across the glass and the body with a grease pencil. (Scheme 23): Locating Alignment Marks Across Glass And Body
- Pull down the front portion of the headliner (see «HEADLINER REMOVAL/INSTALLATION»(ref-371409-S37927230862010091000000) ). Take care not to bend the headliner excessively, or you may crease or break it.
- 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 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.
- 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. (Scheme 24): Pulling Piano Wire Back And Forth In Sawing Motion Cutting portions (Scheme 25): Identifying Cutting Portions
- Carefully remove the windshield.
- Use a knife, scrape the old adhesive smooth to 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 the fasteners from the body.
- 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.
- If you are reinstalling the old windshield, use a putty knife to scrape off all of the old adhesive, the clips and the rubber dam from the windshield. 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.
- Apply primer to the upper clip mounting areas on the windshield (A), and let it dry. Remove the adhesive backing and attach the side rubber dam (B), the upper rubber dam (C), and the upper clips (D) to the inside face of the windshield as shown: Be sure the rubber dams and the clips line up with the alignment marks (E, F, G). Be careful not to touch the windshield where the adhesive will be applied. (Scheme 26): Applying Primer To Upper Clip Mounting Areas On Windshield
- Attach the molding (A) with adhesive tape to the upper edge of the windshield (B). Be careful not to touch the windshield where the adhesive will be applied. (Scheme 27): Attaching Molding With Adhesive Tape To Upper Edge Of Windshield
- 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. (Scheme 28): Applying Primer To Molding
- Set the windshield (A) in the opening, and center it. Make alignment marks (B) across the windshield and the body with a grease pencil at the four points shown. Make sure the pins (C) of both upper clips (D) contact with the edge of the body holes. Be careful not to touch the windshield where the adhesive will be applied. (Scheme 29): Locating Windshield, Pins And Upper Clips
- Remove the windshield.
- With an applicator, apply a light coat of glass primer to the windshield (A) along the edge of the rubber dams (B, C) and the molding (D) 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 mix up body and glass primer applicator. 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 the primed surfaces. (Scheme 30): Applying Light Coat Of Glass Primer To Windshield Along Edge Of Rubber Dams And Molding
- With an applicator, carefully apply a light coat of body primer to any exposed paint or metal around the flange where the adhesive will be applied. Let the body primer dry for at least 10 minutes: Be careful not to mix up the body and the glass primer applicator. Never touch the primed surfaces with your hands. Do not apply body primer to any remaining original adhesive on the flange. (Scheme 31): Applying Light Coat Of Body Primer To Any Exposed Paint Or Metal Around Flange Where Adhesive Will Be Applied
- Cut a "V" in the end of the nozzle (A) on the adhesive cartridge as shown. (Scheme 32): Identifying V Cut In End Of Nozzle On Adhesive Cartridge
- Put the cartridge in a caulking gun, and run a continuous bead of adhesive (A) on the windshield (B) along the edge of the molding (C) and the rubber dams (D) as shown. Apply the adhesive within 30 minutes after applying the glass primer. Make a slightly thicker bead at each corner. (Scheme 33): Applying Continuous Bead Of Adhesive On Windshield Along Edge Of Molding And Rubber Dams
- Use suction cups to hold the windshield over the opening, align it with the alignment marks made in step 14, 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 the doors for about an hour until the adhesive is dry.
- Remove the excess adhesive with a putty knife or a shop towel dampened with isopropyl alcohol.
- Wait at least an hour for the adhesive to dry, then spray water over the windshield and check for leaks. Mark leaking areas, and 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.
- Reinstall all remaining removed parts. Install the rearview mirror after the adhesive has dried thoroughly. 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).
Rear Window Replacement
Note. Put on gloves to protect your hands. Wear eye protection when removing the glass with piano wire. Use seat covers to avoid damaging any surfaces. Do not damage the rear window defogger grid lines or the terminals.
Scheme 34
Scheme 35
Scheme 36
Scheme 37
Scheme 38
Scheme 39
Scheme 40
Scheme 41
Scheme 42
Scheme 43
Scheme 44
Scheme 45
- Remove these items: Tailgate lower trim panel (see «TRIM REMOVAL/INSTALLATION-TAILGATE AREA»(ref-371409-S03789621112010091000000) ) High mount brake light (see «HIGH MOUNT BRAKE LIGHT REPLACEMENT»(ref-371402-S10893607042010091000000) ) Rear window washer nozzle (see «REAR WINDOW»(ref-371411-S04554388932010091000000) ) Rear window wiper arm (see «REAR WINDOW»(ref-371411-S24542319212010091000000) )
- Remove the lower rubber dam (A) and the side rubber dams (B) from the edges of the rear window (C). If necessary/cut the rubber dams with a utility knife. (Scheme 34): Locating Lower Rubber Dam, Side Rubber Dams And Rear Window
- Disconnect the rear window defogger connectors (A). (Scheme 35): Locating Rear Window Defogger Connectors
- If you are reinstalling the old rear window, make alignment marks (A) across the glass and the body with a grease pencil. (Scheme 36): Identifying Alignment Marks Across Glass
- Apply protective tape along the inside and the outside edges of the tailgate. Make a hole with an awl through the adhesive from inside the vehicle at the corner of the rear window. Push a piece of piano wire through the hole, and wrap each end around a piece of wood.
- 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 rear window (B) as possible to prevent damage to the tailgate, and carefully cut through the adhesive (C) around the entire rear window. (Scheme 37): Pulling Piano Wire Back And Forth In Sawing Motion Cutting portions (Scheme 38): Identifying Cutting Portions
- Carefully remove the rear window.
- Use a knife, scrape the old adhesive smooth to a thickness of about 2 mm (0.08 in) on the bonding surface around the entire rear window opening flange: Do not scrape down to the painted surface of the body; damaged paint will interfere with proper bonding. Remove the fasteners from the tailgate.
- Clean the tailgate bonding surface with a shop towel dampened in isopropyl alcohol. After cleaning, keep oil, grease and water from getting on the surface.
- If you are reinstalling the old rear window, use a putty knife to scrape off all of the old adhesive, the fasteners and the rubber dams from the rear window. Clean the bonding surface on the inside face and the edge of the rear window with isopropyl alcohol. Make sure the bonding surface is kept free of water, oil, and grease.
- Apply primer to the fasteners and rubber dams mounting areas on the rear window, and let it dry. Attach the upper rubber dam (A), the side rubber dams (B), the fasteners (C), and the lower rubber dam (D) with the adhesive tape to the inside face of the rear window (E) a shown. Be sure the fasteners and the upper rubber dam line up with alignment marks (F). Be careful not to touch the rear window where the adhesive will be applied. (Scheme 39): Applying Primer To Fasteners And Rubber Dams Mounting Areas On Rear Window
- Cut the excess side rubber dam and the lower rubber dam along both beveled edges of the rear window.
- Attach the fasteners (A, B) with adhesive tape to the tailgate as shown. (Scheme 40): Locating Fasteners With Adhesive Tape On Tailgate
- Set the rear window (A) in the opening, and center it. Make alignment marks (B) across the rear window and the body with a grease pencil at the four points shown. Make sure the pins (C) of both clips (D) contact with the holes of the tailgate corner. Be careful not to touch the rear window where the adhesive will be applied. (Scheme 41): Locating Rear Window, Pins And Clips
- Remove the rear window.
- With an applicator, apply a light coat of glass primer to the rear window (A) along the edge of the rubber dams (B) as shown, then lightly wipe it off with gauze or cheesecloth: Apply the glass primer to the corner portions of the rear window using the printed dots (C) on the rear window as a guide. Do not apply body primer to the rear window, and do not mix up the body and the glass primer applicator. Never touch the primed surfaces with your hands. If you do, the adhesive may not bond to the rear window properly, causing a leak after the rear window is installed. Keep water, dust, and abrasive materials away from the primed surface. (Scheme 42): Applying Light Coat Of Glass Primer To Rear Window Along Edge Of Rubber Dams
- With an applicator, carefully apply a light coat of body primer to any exposed paint or metal around the flange where the adhesive will be applied. Let the body 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 applicator. Never touch the primed surfaces with your hands. (Scheme 43): Applying Light Coat Of Body Primer To Any Exposed Paint Or Metal Around Flange Where Adhesive Will Be Applied
- Cut a "V" in the end of the nozzle (A) on the adhesive cartridge as shown. (Scheme 44): Identifying V Cut In End Of Nozzle On Adhesive Cartridge
- Put the cartridge in a caulking gun, and run a continuous bead of adhesive (A) to the rear window (B) and along the edge of the rubber dams (C) as shown. Use the printed dots (D) as a guide when you apply the adhesive to the corners of the rear window. Apply the adhesive within 30 minutes after applying the glass primer. Make a slightly thicker bead at each corner. (Scheme 45): Applying Continuous Bead Of Adhesive To Rear Window And Along Edge Of Rubber Dams
- Use suction cups to hold the rear window over the opening, align it with the alignment marks you made in step 14, and set it down on the adhesive. Lightly push on the rear window 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.
- Remove the excess adhesive with a putty knife or a shop towel dampened with isopropyl alcohol.
- Wait at least an hour for the adhesive to dry, then spray water over the rear window and check for leaks. Mark the leaking areas, let the rear window dry, then seal with sealant. Let the vehicle stand for at least 4 hours after rear window installation. If the vehicle has to be used within the first 4 hours, it must be driven slowly.
- 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).
Note. Put on gloves to protect your hands. Wear eye protection when removing the glass with piano wire. Use seat covers to avoid damaging any surfaces. The quarter glass molding will need replacement because it will be damage during glass removal.
Scheme 46
Scheme 47
Scheme 48
Scheme 49
Scheme 50
Scheme 51
Scheme 52
Scheme 53
Scheme 54
Scheme 55
Scheme 56
Scheme 57
Scheme 58
Scheme 59
- Remove the quarter pillar glass trim (see «QUARTER PILLAR GLASS TRIM»(ref-371409-S41230513932010091000000) ).
- Remove the front seal (A) from the front edge of the quarter glass (B). If necessary, cut the seal with a utility knife. (Scheme 46): Removing Front Seal From Front Edge Of Quarter Glass
- If the old quarter glass (A) is to be reinstalled, make alignment marks (B) across the glass and the body with a grease pencil over the quarter glass molding (C). (Scheme 47): Identifying Alignment Marks Across Glass And Body
- Apply protective tape along the inside and outside edges of the body. From pillar side the vehicle, use a knife (A) to cut the front clips (B) of the quarter glass molding (C). (Scheme 48): Cutting Front Clips Of Quarter Glass Molding
- Make a hole with an awl through the adhesive from inside the vehicle at the front corner of the quarter glass. Push a piece of piano wire through the hole, and wrap each end around a piece of wood.
- 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 quarter glass (B) as possible to prevent damage to the body, and carefully cut through the adhesive (C) in the straight areas and front corner, but not the rear corner. (Scheme 49): Pulling Piano Wire Back And Forth In Sawing Motion Cutting portions (Scheme 50): Identifying Cutting Portions
- From inside the vehicle, use a knife (A) to cut the rear clip (B) of the quarter glass molding, then cut through the adhesive (C) of the quarter glass rear corner. (Scheme 51): Cutting Rear Clip Of Quarter Glass Molding
- Carefully remove the quarter glass and the quarter glass molding. Replace the molding with a new one.
- With a knife, scrape the old adhesive smooth to a thickness of about 2 mm (0.08 in) on the bonding surface around the entire quarter glass opening flange: Do not scrape down to the painted surface of the body; damaged paint will interfere with proper bonding. Remove the molding from the quarter glass.
- Clean the body bonding surface with a shop towel dampened in isopropyl alcohol. After cleaning, keep oil, grease, and water from getting on the surface.
- If you are reinstalling the old quarter glass, use a putty knife to scrape off all of the old adhesive and the clips from the quarter glass. Clean the bonding surface on the inside face and the edge of the quarter glass with isopropyl alcohol. Make sure the bonding surface is kept free of water, oil, and grease.
- Apply primer to the clip mounting areas on the quarter glass, and let it dry. Attach the upper clip (A), the lower clip (B), and the front seal (C) with the adhesive tape to the inside face of the quarter glass (D) as shown. Be careful not to touch the glass where the adhesive will be applied. Be sure installing the clips with its convex portions (E) downward. (Scheme 52): Locating Upper Clip, Lower Clip, Front Seal And Quarter Glass
- Set the quarter glass (A) in the opening, and make alignment marks (6) across the quarter glass and the body with a grease pencil at the three points shown. Make sure pins (C) of the both clips (D) contact with the edge of the body holes. Be careful not to touch the glass where the adhesive will be applied. (Scheme 53): Locating Quarter Glass, Pins And Clips
- Remove the quarter glass.
- Install the quarter glass molding (A). Hold the molding up on the glass, and fit the hooks (B) of the molding to the edge of the glass rear corner first. From the rear corner to the front, hook the lower clip (C) and the upper clips (D) of the molding to along the edges of the glass. Push the molding into place securely. NOTE: Take care not to bend or damage the molding. Be careful not to touch the glass where the adhesive will be applied. Be sure the front seal contacts the upper and lower ends of the molding. (Scheme 54): Installing Quarter Glass Molding
- With an applicator, apply a light coat of glass primer to the quarter glass (A) along the edge of the front seal (B) as shown, then lightly wipe it off with gauze or cheesecloth: Apply the glass primer to the corner portions of the quarter glass using the printed dots (C) on the quarter glass as a guide. Do not apply body primer to the quarter glass, and do not mix up the body and the glass primer applicator. Never touch the primed surfaces with your hands. If you do, the adhesive may not bond to the quarter glass properly, causing a leak after the quarter glass is installed. Keep water, dust, and abrasive materials away from the primed surface. (Scheme 55): Applying Light Coat Of Glass Primer To Quarter Glass Along Edge Of Front Seal
- With an applicator, carefully apply a light coat of body primer to any exposed paint or metal around the flange where the adhesive will be applied. Let the body 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 applicator. Never touch the primed surfaces with your hands. (Scheme 56): Applying Light Coat Of Body Primer To Any Exposed Paint Or Metal Around Flange Where Adhesive Will Be Applied
- Cut a "V" in the end of the nozzle (A) on the adhesive cartridge as shown. (Scheme 57): Identifying V Cut In End Of Nozzle On Adhesive Cartridge
- Put the cartridge in a caulking gun, and run a continuous bead of adhesive (A) to the quarter glass (B) along the front seal (C) as shown. With the printed dots on the quarter glass as a guide, apply the adhesive to the rear corner, upper corner, and lower corner portions of the quarter glass. Apply the adhesive within 30 minutes after applying the glass primer. Make a slightly thicker bead at each corner. Use the printed dots (D) as a guide when you apply the adhesive to the corners of the quarter window. (Scheme 58): Applying Continuous Bead Of Adhesive To Quarter Glass Along Front Seal
- Use suction cups (A) to hold the quarter glass (B) over the opening, align it with the clips (C) and alignment marks (D) you made in step 13, and set it down on the adhesive. Lightly push on the quarter glass 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. (Scheme 59): Aligning Quarter Glass With Clips And Alignment Marks
- Remove the excess adhesive with a putty knife or a shop towel dampened with isopropyl alcohol.
- Wait at least an hour for the adhesive to dry, then spray water over the quarter glass and check for leaks. Mark the leaking areas, let the quarter glass dry, then seal with sealant. Let the vehicle stand for at least 4 hours after quarter glass installation. If the vehicle has to be used within the first 4 hours, it must be driven slowly.
- 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).