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Windshield Replacement

NOTE:
  • Put on gloves to protect your hands.
  • Wear eye protection while cutting the glass adhesive with piano wire.
  • Cover interior surfaces to avoid damaging them.
  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.
    Fig 1: View Of Molding From Upper Edge Of Windshield
    G06162260Courtesy 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 the 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 the dashboard. Carefully cut through the rubber dam and adhesive (C) around the entire windshield.
    Fig 2: Cutting Rubber Dam & Adhesive Around Windshield
    G06162261Courtesy of AMERICAN HONDA MOTOR CO., INC.

    Cutting positions 

    Fig 3: Identifying Rubber Dam & Adhesive Cutting Positions
    G06162262Courtesy 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 dam and the fasteners from the body.
    • Replace the dashboard seal with a new one.
  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 all of the old adhesive, the upper clips, and the rubber dam. 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. Attach the upper rubber dam (A), the lower rubber dam (B) with adhesive tape A, and the clips (C) with adhesive tape B to the inside face of the windshield (D) as shown below:
    • Be sure the rubber dam and the clips line up with the alignment marks (E).
    • Be careful not to touch the windshield where adhesive will be applied.

    Adhesive tape A: Thickness 0.16 mm (0.006 in.) 

    Adhesive tape B: Thickness 0.4 mm (0.02 in.) 

    Width 10 mm (0.39 in.) 

    Fig 4: Identifying Adhesive Tape Applying Area
    G06162263Courtesy of AMERICAN HONDA MOTOR CO., INC.
  12. 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.

    Adhesive tape: Thickness 0.8 mm (0.03 in.) 

    Width 4 mm (0.2 in.) 

    Fig 5: Attaching Molding With Adhesive Tape To Upper Edge Of Windshield
    G06162264Courtesy of AMERICAN HONDA MOTOR CO., INC.
  13. Attach the molding upper seal (A) to the inside surface of the molding (B) as shown below.
    Fig 6: Attaching Molding Upper Seal To Inside Surface Of Molding
    G06162265Courtesy of AMERICAN HONDA MOTOR CO., INC.
  14. 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 both clips (B) contact the edge of the body holes. Be careful not to touch the windshield where adhesive will be applied.
    Fig 7: Identifying Alignment Marks On Windshield & Body
    G06162266Courtesy of AMERICAN HONDA MOTOR CO., INC.
  15. Remove the windshield.
  16. With a sponge applicator, apply a light coat of glass primer around the edge of the windshield (A) between the dams (B) and the molding (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 sponge applicators 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 8: Identifying Glass Primer Applying Area On Molding
    G06162267Courtesy of AMERICAN HONDA MOTOR CO., INC.
  17. With a sponge applicator, carefully apply a light coat of body primer to any exposed paint 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 sponge applicators.
    • Never touch the primed surfaces with your hands.
    Fig 9: Applying Light Coat Of Body Primer To Exposed Paint Around Flange
    G06162268Courtesy of AMERICAN HONDA MOTOR CO., INC.
  18. Cut a "V" in the end of the nozzle (A) on the adhesive cartridge as shown below.
    Fig 10: Identifying Nozzle Cutting Dimension
    G06162269Courtesy of AMERICAN HONDA MOTOR CO., INC.
  19. Put the cartridge in a caulking gun, and run a bead of adhesive (A) around the edge of the windshield (B) between the dams (C) and the molding (D) as shown below. Apply the adhesive within 30 minutes after applying the glass primer. Make a slightly thicker bead at each corner.
    Fig 11: Applying Adhesive Around Edge Of Windshield Between Dams & Molding
    G06162270Courtesy of AMERICAN HONDA MOTOR CO., INC.
  20. 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. Do not open or close any of the doors for about an hour until the adhesive is dry.
  21. Scrape or wipe any 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.
  22. After the adhesive has dried, spray water over the windshield and check for leaks. Mark any 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.
    • Keep the windshield dry for the first hour after installation.
  23. Reinstall all remaining removed parts.
    NOTE: Advise the client 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).
    • 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.
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