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Windshield Glass: Installation

CAUTION:
  • After installing the urethane installed glass, the vehicle should not be driven until the urethane has cured. The curing time for temperatures above 13°C (55°F) and relative humidity above 50% is 12-24 hours. (See Drive Away chart for cure times as temperature and humidity vary). Inadequate curing of the urethane may adversely affect the strength of the urethane bond.
CAUTION:
  • Open the windows to prevent the windshield glass from being pushed out by air pressure if doors are closed.
  1. Dry fit the windshield. Make alignment marks with tape or non-staining pencil.
    Fig 1: Removing Urethane Adhesive On Pinch Weld
    G04322680Courtesy of MAZDA MOTORS CORP.
    CAUTION:
    • Do not scratch pinch weld area.
  2. Trim the remaining urethane adhesive on the pinch weld to within specification. The surface should be smooth and free of cuts and contamination.
  3. Use the wool applicator to apply metal primer to any exposed metal on the pinch weld. Allow six to ten minutes to dry.
  4. If reinstalling the original windshield, remove excess urethane adhesive from the windshield glass
  5. Clean the inside of the glass surface with an alcohol-free cleaner making sure the ceramic-coated area is clean.
    CAUTION:
    • Wipe off urethane glass prep immediately after each application because it flash dries.
  6. If installing a new windshield, apply glass prep twice around the glass surface.
  7. If installing a new windshield, apply glass primer to the same area that was prepped in the previous step. Allow five minutes to dry.
    Fig 2: Applying Foam Dam To Bottom Of Windshield Glass
    G04322681Courtesy of MAZDA MOTORS CORP.
  8. Apply foam dam to the bottom of the windshield glass.
    Fig 3: Cutting Urethane Applicator Tip
    G04322682Courtesy of MAZDA MOTORS CORP.
  9. Cut the urethane applicator tip to specification.
    Fig 4: Applying Bead Of Urethane Adhesive To Sides And Top Of Windshield Glass
    G04322683Courtesy of MAZDA MOTORS CORP.
  10. Apply a bead of urethane adhesive to the sides and top of the windshield glass.
    Fig 5: Applying Bead Of Urethane Adhesive To Bottom Of Windshield Glass Outside Foam Dam
    G04322684Courtesy of MAZDA MOTORS CORP.
  11. Apply a bead of urethane adhesive to the bottom of the windshield glass outside the foam dam.
  12. Install the windshield by aligning it to the marks previously made.
    CAUTION:
    • Carry out this step after the urethane has cured.
  13. Check the windshield glass installation for air or water leaks through the urethane seal.
  14. If necessary, remove excess urethane adhesive from the outside surface of the windshield glass.
  15. Install the cowl grille. See COWL PANEL GRILLE
  16. Reposition the front portion of the headliner.
    Fig 6: Installing Overhead Console
    G04322685Courtesy of MAZDA MOTORS CORP.
  17. Install the overhead console.
    1. Position the overhead console, If equipped, connect the electrical connector.
    2. Install the screws.
      Fig 7: Installing Sunvisor Clips
      G04322686Courtesy of MAZDA MOTORS CORP.
  18. Install the two sunvisor clips
    1. Position the sun visors and clips.
    2. Install the six screws.
  19. Install the rear view mirror.
    Fig 8: Installing Windshield Side Garnish Mouldings
    G04322687Courtesy of MAZDA MOTORS CORP.
  20. Install the two windshield side garnish mouldings.
  21. Install the two A - pillar passenger assist handles.
    1. Position the two assist handles.
    2. Install the four bolts.
    3. Close the four assist handle covers.
  22. Install the driver and passenger assist handles.
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