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. 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. Do not damage the windshield defogger grid lines or the defogger terminals.
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- Remove these items: Rearview mirror (see «REARVIEW MIRROR REPLACEMENT»(ref-336507-S02123639512009072700000) ) A-pillar trim, both sides (see «TRIM REMOVAL/INSTALLATION - PILLAR AREAS»(ref-336498-S03419188692009072700000) ) Windshield wiper arms (see «WIPER MOTOR REPLACEMENT»(ref-336510-S02760330592009072700000) ) Cowl cover (see «COWL COVER REPLACEMENT»(ref-336480-S08223417562009072700000) ) Right tweeter grille (see «DASHBOARD/STEERING HANGER BEAM REMOVAL/INSTALLATION»(ref-336501-S26304819402009072700000) )
- Lower the glove box (see «DASHBOARD CENTER LOWER COVER DISASSEMBLY/REASSEMBLY»(ref-336501-S06814314892009072700000) ).
- Disconnect the windshield defogger connector (A) through the glove box opening, and pull out the windshield defogger harness (B) from the tweeter grille opening in the dashboard (C).
- Remove the molding (A) from the edge of the windshield (B). If necessary, cut the molding with a utility knife.
- If the old windshield will be reinstalled, make alignment marks across the glass and body with a grease pencil.
- Pull down the front portion of the headliner (see «HEADLINER REMOVAL/INSTALLATION»(ref-336498-S08368389162009072700000) ). 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 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.
- Apply the protective plastic plates (A) between the dashboard (B) and the piano wire (C), and between the windshield (D) and the piano wire. With a helper on the outside, pull the piano wire back and forth in a sawing motion. Hold the piano wire as close to the windshield as possible to prevent damage to the body and the dashboard. Carefully cut through the rubber dam and the adhesive (E) around the entire windshield. Take care not to damage the windshield defogger harness (F).
- Carefully remove the windshield.
- Scrape smooth the old adhesive with a knife 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 the fasteners from the body.
- Clean the body bonding surface with a sponge dampened in isopropyl alcohol. After cleaning, keep oil, grease and water from getting on the clean surface.
- If you are reinstalling the old windshield, scrape off all of the old adhesive, the rubber dams 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.
- Apply glass primer to the fastener mounting area on the windshield (A), and let it dry. Remove the adhesive backing and attach the upper rubber dam (B), the side rubber dams (C), the lower rubber dam (D), the fasteners (E), and the dashboard seal (F) to the inside face of the windshield as shown. Be sure the rubber dams, the fasteners, and the dashboard seal line up with the alignment marks (G). Be careful not to touch the windshield where adhesive will be applied.
- Apply primer to the edge of the windshield between the alignment marks (A). Be careful not to touch the windshield where adhesive will be applied.
- Attach the molding (A) with adhesive tape (B) to the edge of the windshield (C): Be sure the alignment mark (D) of the molding lines up with the alignment mark (E) of the windshield. Be careful not to touch the windshield where adhesive will be applied.
- Attach the molding upper seals (A), the molding side seals (B), and the non woven fabric (C) to the inside surface of the molding (D), and attach the molding rubbers (E) with the adhesive tape to the inside surface of the molding lip (F) as shown: Be sure the molding upper seal and the molding side seal line up with the alignment dots (G). Be sure the molding rubber lines up with the alignment mark (H) of the molding. Be careful not to touch the windshield where adhesive will be applied.
- Install the fasteners to the body.
- If you are installing a new windshield, 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. Be careful not to touch the windshield where the adhesive will be applied.
- Remove the windshield.
- Apply a light coat of glass primer to the windshield (A) along the edge of the upper rubber dam (B), the side rubber dams (C), the lower rubber dam (D), and the molding (E) 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 the body primer applicator and the 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.
- Carefully apply a light coat of body primer to any exposed paint around the flange where the 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 primer applicator and the glass primer applicator. Never touch the primed surface with your hands. Cover on the dashboard before applying the primer.
- Cut a ''V" in the end of the nozzle (A) on the adhesive cartridge as shown.
- Put the cartridge in a caulking gun, and run a continuous bead of the adhesive (A) around the edge of the windshield (B) between the upper rubber dam (C), the side rubber dams (D), the lower rubber dam (E), and the molding (F) as shown. Apply the adhesive within 30 minutes after applying the glass primer. Make a slightly thicker bead at each corner.
- Hold the windshield with suction cups over the opening, align it with the alignment marks you made in step 18, 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.
- 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 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).
Back Window Replacement
Note. Put on gloves to protect your hands. Use seat covers to avoid damaging any surface.
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- Remove these items: Rear seat assembly (see «REAR SEAT REMOVAL/INSTALLATION»(ref-336496-S28083561212009072700000) ) C-pillar trim, both sides (see «C-PILLAR TRIM»(ref-336498-S06951927242009072700000) ) Rear seat belt lower anchor, both sides (see step 2 on «REAR SEAT BELT REPLACEMENT»(ref-336511-S01882835242009072700000) ) Rear seat side trim, both sides (see step 9 on «TRIM REMOVAL/INSTALLATION - DOOR AREAS»(ref-336498-S00856079632009072700000) ) Subwoofer for some models (see «SUBWOOFER»(ref-336512-S06466092292009072700000) ) Rear panel insulator (see «REAR PANEL INSULATOR REPLACEMENT»(ref-336498-S22378854632009072700000) ) Back window middle glass regulator (see «BACK WINDOW MIDDLE GLASS REGULATOR REPLACEMENT»(ref-336509-S26823855722009072700000) ) Bed rail trim (see «BED RAIL TRIM REPLACEMENT»(ref-336503-S42722203942009072700000) ) Rear roof trim (see «REAR ROOF TRIM REPLACEMENT»(ref-336480-S32616567822009072700000) ) Front bed panel (see «FRONT BED PANEL REMOVAL/INSTALLATION»(ref-336503-S28548255532009072700000) ) Cargo area front light (see «HIGH MOUNT BRAKE LIGHT REPLACEMENT»(ref-336477-S16840856962009072700000) ) C-pillar outer trim (see «C-PILLAR OUTER TRIM REPLACEMENT»(ref-336503-S21821128002009072700000) ) Side bed panel (see «SIDE BED PANEL REMOVAL/INSTALLATION»(ref-336503-S25533465512009072700000) )
- Disconnect the connector (A) and detach the harness clip (B). Remove the screws (C), then remove the back power window position switch (D).
- Pull down the rear portion of the headliner as needed (see «HEADLINER REMOVAL/INSTALLATION»(ref-336498-S08368389162009072700000) ). Take care not to bend the headliner excessively, or you may crease or break it.
- From inside the vehicle, use a utility knife (A) to cut through the adhesive (B) all the way around: If the back window (C) will be reinstalled, take care not to damage the molding (D). Apply protective tape along the edge of the entire back window opening flange.
- Carefully remove the back window. Check the molding for damage, and replace it if necessary.
- Scrape smooth the old adhesive with a knife until there is a thickness of about 2 mm (0.08 in) on the bonding surface around the entire back 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 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 surface.
- If you are reinstalling the old back window, scrape off all of the old adhesive and the fasteners from the back window molding with a putty knife. Clean the bonding surfaces on the inside face and the edge of the back window molding with isopropyl alcohol. Make sure the bonding surface is kept free of water, oil and grease.
- Attach the fasteners (A) with adhesive tape to the back window molding (B) as shown: Be sure the fasteners line up with the alignment marks (C) and molding shapes (D). Be careful not to touch the back window molding where the adhesive will be applied.
- Attach the fasteners with adhesive tape to the back window opening flange of the body on both sides.
- Set the back window in the opening, and center it. Make alignment marks (A) across the back window and the body with a grease pencil at the four points shown. Make sure insert nuts (B) are aligned in the body holes (inside). Be careful not to touch the back window molding where the adhesive will be applied.
- Remove the back window.
- Apply a light coat of glass primer along the edge of the back window molding (A) as shown, then lightly wipe it off with gauze or cheesecloth: Do not apply body primer to the back window, and do not mix up the body primer applicator and the glass primer applicator. Never touch the primed surfaces with your hands. If you do, the adhesive may not bond to the back window properly, causing a leak after the back window is installed. Keep water, dust, and abrasive materials away from the primed surfaces.
- Carefully apply a light coat of body primer to any exposed paint around the flange where the 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 primer applicator and the glass primer applicator. Never touch the primed surfaces with your hands.
- Cut a "V" in the end of the nozzle (A) on the adhesive cartridge as shown.
- Put the cartridge in a caulking gun, and run a continuous bead of the adhesive (A) around the edge of the back window molding (B) as shown. Apply the adhesive within 30 minutes after applying the glass primer. Make a slightly thicker bead at each corner.
- Hold the back window with suction cups over the opening, align it with the alignment marks you made in step 11, and set it down on the adhesive. Lightly push on the back 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 back window and check for leaks. Mark any leaking areas, let the back window dry, then seal with sealant. Let the vehicle stand for at least 4 hours after back window installation. If the vehicle is used within the first 4 hours, it must be driven slowly.
- Reinstall all 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. Take care not to bend or scratch the trim or the panels.
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- Remove these items: Rear seat assembly (see «REAR SEAT REMOVAL/INSTALLATION»(ref-336496-S28083561212009072700000) ) C-pillar trim, both sides (see «C-PILLAR TRIM»(ref-336498-S06951927242009072700000) ) Rear seat belt lower anchor (see «REAR SEAT BELT REPLACEMENT»(ref-336511-S01882835242009072700000) ) Rear seat side trim, both sides (see «TRIM REMOVAL/INSTALLATION - DOOR AREAS»(ref-336498-S00856079632009072700000) ) Subwoofer for some models (see «SUBWOOFER»(ref-336512-S06466092292009072700000) ) Rear panel insulator (see «REAR PANEL INSULATOR REPLACEMENT»(ref-336498-S22378854632009072700000) )
- Remove the back window middle glass mounting bolts.
- Disconnect the connector (A) from the regulator motor (B).
- Remove the bolts (C, D), and detach the cable clips (E), then remove the regulator (F) and motor.
- Apply multipurpose grease to the sliding surfaces of the regulator (A) where shown.
- Install the regulator in the reverse order of removal, and note these items
- Slide the glass right and left to make sure it moves freely without binding.
- Make sure the connector is plugged in properly.
Note. Put on gloves to protect your hands. Take care not to bend or scratch the trim or the panels.
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- Remove these items: Rear seat-back (see «REAR SEAT-BACK REMOVAL/INSTALLATION»(ref-336496-S28275187032009072700000) ) Rear trim panel (see step 2 on «C-PILLAR TRIM»(ref-336498-S06951927242009072700000) )
- Remove the back window middle glass mounting bolts.
- Open the middle glass (A) fully by hand. Insert a pick tool (B) into the glass run channel (C) as shown, and pull out the edge of the upper spacer (D), then pull out the spacer by hand from between the glass run channel and the glass.
- Move the glass (A) until you can remove it as shown. Pull up the glass to release the bottom of the glass, then pull out the top of the glass from the glass run channel (B). Carefully remove the glass.
- Install the glass in the reverse order of removal, and note these items
- Make sure the spacer is installed properly.
- Slide the glass to make sure it moves freely without binding.
- Make sure that there is no clearance between the glass and the glass run channel when the glass is closed.
- Check for water leaks (see step 8 on «FRONT AND REAR DOOR GLASS ADJUSTMENT»(ref-336506-S17296272822009072700000) ).
- Test-drive, and check for wind noise and rattles.
Note. Put on gloves to protect your hands. Take care not to bend or scratch the trim or the panels.
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- Remove the back window middle glass (see «BACK WINDOW MIDDLE GLASS REPLACEMENT»(ref-336509-S03476060612009072700000) ).
- Carefully cut the glass run channel (A) on the middle glass areas (B) with a utility knife (C), and then pull out the glass run channel from the top and bottom groove areas of the back window molding (D). Take care not to damage the molding.
- Check the molding for damage, and replace if necessary.
- Scrape out the remaining glass run channels (A) with a knife or similar tool from the grooves (B) in the middle glass areas of the back window molding (C).
- Clean the molding bonding surface with a shop towel dampened in isopropyl alcohol. After cleaning, keep oil, grease and water from getting on the clean surface.
- Apply a light coat of primer to the groove areas (A) of the back window molding (B). Install the glass run channel (C) to the top and bottom groove areas of the molding, and then attach the glass run channel to the middle glass areas of the molding with structural adhesive (3M DP8005).
- Remove the excess adhesive with a shop towel dampened with isopropyl alcohol.
- Reinstall all removed parts.