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Windshield Glass Removal/Installation: Installation

WARNING:
  • Do not drive vehicle until the urethane seal has cured. Follow urethane manufacturer's curing directions. Inadequate or incorrect curing of the urethane seal will adversely affect glass retention. Failure to follow these instructions may result in serious Injury to vehicle occupant(s).
CAUTION:
  • Open the windows to prevent the windshield glass from being pushed out by air pressure if the doors are closed.
WARNING:
  • Open the windows to prevent the windshield glass from being pushed out by air pressure if the doors are closed.
  1. Dry fit the windshield glass, making alignment marks with tape or a non-staining grease pencil.
  2. Trim the remaining urethane adhesive on the pinch weld to within the specification.
    • The existing urethane adhesive surface should be smooth and free of cuts and contamination.
      Fig 1: Identifying Urethane Adhesive Specification
      G05466010Courtesy of MAZDA MOTORS CORP.
    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:
    • Do not scratch the pinch weld area. For minor scratches or exposed metal on the pinch weld, see manufacturer's recommendations.
  3. If reinstalling the original windshield glass, remove the excess urethane adhesive and the windshield moulding.
  4. Clean the inside of the windshield glass surface with glass cleaner making sure the ceramic-coated area is clean.
  5. If installing a new windshield glass, apply urethane glass primer according to manufacturer's instructions. Allow at least 6 minutes to dry.
    NOTE:
    • Be sure to use the same brand and cure-rate products for the adhesive and primer. Do not mix different brands of urethane and primer.
    NOTE:
    • Sika uses the same black primer for the glass and pinch weld area.
  6. Cut the urethane adhesive applicator tip to specification.
    Fig 2: Cutting Urethane Applicator Tip With Specifications
    G05466011Courtesy of MAZDA MOTORS CORP.
  7. Apply urethane adhesive on top of the existing trimmed urethane adhesive bead on the pinch weld. Make sure that all gaps in the urethane adhesive are smoothed into one continuous bead starting and ending at the bottom of the windshield near the center.
    NOTE:
    • Use either a high-ratio electric or battery-operated caulk gun that will apply the urethane with less effort and a continuous bead.
  8. Install the windshield glass, aligning it to the marks previously made.
  9. After the urethane adhesive has cured, check for water leaks and add urethane adhesive where needed.
    NOTE:
    • The urethane adhesive must cure for a minimum of one hour before testing for air and water leaks.
  10. If necessary, remove excess urethane adhesive from the exterior surface of the windshield glass.
  11. Install the cowl grille. See COWL PANEL GRILLE REMOVAL/INSTALLATION .
  12. Reposition the front portion of the headliner.
  13. Install the LH and RH sun visors and visor clips.
    • If equipped, connect the electrical connectors.
  14. Install the interior rear view mirror. See REAR VIEW MIRRORS .
  15. Position the overhead console and install the 2 overhead console screws.
    • If equipped, connect the electrical connector.
  16. Install the 2 windshield side garnish mouldings.
  17. Install the LH and RH A-pillar trim panels. See INTERIOR TRIM PANELS - EXPLODED VIEW .
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