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Windshield Replacement

NOTE:
  • Put on gloves to protect your hands
  • Wear eye protection while cutting the glass adhesive with a 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 instructions of the tool manufacturer
  1. Remove these items
  2. Remove the molding (A) from the upper edge of the windshield (B) If necessary, cut the molding with a utility knife
    3. Fig 1: Removing Molding From Upper Edge Of Windshield
    G05994138Courtesy of AMERICAN HONDA MOTOR CO., INC.
  3. If the old windshield will be reinstalled, make alignment marks across the glass and the body with a grease pencil
  4. Pull down the front portion of the headliner (see HEADLINER REMOVAL/INSTALLATION ) Take care not to bend the headliner excessively, or you may crease or break it
  5. Apply protective tape along the edge of the dashboard and body. Using an awl, make a hole through the rubber dam and adhesive from inside the vehicle at the corner portion of the windshield Push a piece of piano wire through the hole, and wrap each end around a piece of wood
  6. 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 dashboard Carefully cut through the rubber dam and adhesive (C) around the entire windshield
    7. Fig 2: Pulling Piano Wire Back And Forth In Sawing Motion
    G05994139Courtesy of AMERICAN HONDA MOTOR CO., INC.

    Cutting positions 

    Fig 3: Identifying Windshield Cutting Positions
    G05994140Courtesy of AMERICAN HONDA MOTOR CO., INC.
  7. Carefully remove the windshield
  8. 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 windshield opening flange
    • Do not scrape down to the painted surface of the body, damaged paint will interfere with proper bonding
    • Remove the rubber dams from the body
  9. 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
  10. If the old windshield will be reinstalled, use a putty knife to scrape off the old adhesive, the upper clips, and the rubber dams from the windshield Clean the inside face and the edge of the windshield with isopropyl alcohol where new adhesive will be applied Make sure the bonding surface is kept free of water, oil, and grease
  11. If the windshield will be replaced with a new one, attach the new rearview mirror harness cover base to the inside face of the windshield (see REARVIEW MIRROR HARNESS COVER BASE REPLACEMENT )
  12. Attach rubber dam A, the upper clips (B), and the dashboard seals (C) with adhesive tape to the inside face of the windshield (D) as shown Before installing the upper clips, apply primer to the area where the adhesive tape will be applied to the inside face of the windshield
    • Be sure the rubber dam, the upper clips, and the dashboard seals line up with the alignment marks (E)
    • Be sure the convex portion (F) of the left and right clips faces the right side
    • Be careful not to touch the windshield where adhesive will be applied

    Rubber dam adhesive tape 

    Thickness 0.16 mm (0 006 in) 

    Width 3.5 mm (014 in) 

    Upper clip adhesive tape 

    Thickness 0 4 mm (0 016 in) 

    Width 10 mm (0 39 in) 

    Dashboard seal adhesive tape 

    Thickness 0 4 mm (0.016 in) 

    Width 13 mm (0 51 in) 

    Fig 4: Identifying Dashboard Seals Applying Area
    G05994141Courtesy of AMERICAN HONDA MOTOR CO., INC.
  13. Attach rubber dam B with adhesive tape to the inside surface of the windshield (A) as shown
    • Be sure the rubber dam lines up with the alignment marks (C)
    • With the edge (D) of the black ceramic on the windshield as a guide, attach rubber dam B to the windshield
    • Be careful not to touch the windshield where adhesive will be applied

    Rubber dam adhesive tape. 

    Thickness 0 16 mm (0.006 in) 

    Width 3.5 mm (014 in) 

    Fig 5: Identifying Rubber Dam Adhesive Tape Applying Area
    G05994142Courtesy of AMERICAN HONDA MOTOR CO., INC.
  14. Attach the molding (A) with adhesive tape (B) to the upper edge of the windshield (C) Be careful not to touch the windshield where adhesive will be applied

    15. Molding adhesive tape. 

    Thickness 0 8 mm (0 03 in) 

    Width 4 mm (016 in) 

    Fig 6: Identifying Molding With Adhesive Tape Applying Area To Upper Edge Of Windshield
    G05994143Courtesy of AMERICAN HONDA MOTOR CO., INC.
  15. Attach the molding upper seal (A) with adhesive tape to the inside surface of the molding (B) as shown
    16. Fig 7: Identifying Molding Upper Seal With Adhesive Tape
    G05994144Courtesy of AMERICAN HONDA MOTOR CO., INC.
  16. 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 Make sure the pins (B) of both upper clips (C) contact with the edge of the body holes Be careful not to touch the windshield where adhesive will be applied
    17. Fig 8: Identifying Windshield Glass Position
    G05994145Courtesy of AMERICAN HONDA MOTOR CO., INC.
  17. Remove the windshield
  18. With a sponge, apply a light coat of glass primer to the windshield (A) along the edge of the molding (B) and the rubber dams (C) 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 get body and glass primer sponges mixed up
    • 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
    Fig 9: Identifying Glass Primer
    G05994146Courtesy of AMERICAN HONDA MOTOR CO., INC.
  19. With a sponge, carefully apply a light coat of body primer to any exposed paint or metal around the flange where new 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 and glass primer sponges
    • Never touch the primed surfaces with your hands
    Fig 10: Applying Light Coat Of Body Primer To Any Exposed Paint
    G05994147Courtesy of AMERICAN HONDA MOTOR CO., INC.
  20. Cut a "V" in the end of the nozzle (A) on the adhesive cartridge as shown
    21. Fig 11: Identifying Sectional View Of Nozzle
    G05994148Courtesy of AMERICAN HONDA MOTOR CO., INC.
  21. Pack adhesive into the cartridge without air pockets to ensure continuous delivery Put the cartridge in a caulking gun, and run a bead of adhesive (A) to the windshield (B) along the edge of the molding (C) and rubber dams (D) as shown Apply the adhesive within 30 minutes after applying the glass primer Make a slightly thicker bead at each corner
    22. Fig 12: Identifying Glass Primer Applying Area
    G05994149Courtesy of AMERICAN HONDA MOTOR CO., INC.
  22. Use suction cups to hold the windshield over the opening, align it with the alignment marks made in step 16, 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
  23. Scrape or wipe the excess adhesive off with a putty knife or towel To remove adhesive from a painted surface or the windshield, wipe with a soft shop towel dampened with isopropyl alcohol
  24. After the adhesive has dried, 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
  25. Reinstall all remaining removed parts
NOTE: Advise the customer not to do the following things for 2 to 3 days
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