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Windshield Replacement

NOTE:
  • Wear eye protection while cutting the glass adhesive with a piano wire.
  • Put on gloves to protect your hands.
  • Use seat covers to avoid damaging any surfaces.
  • Glass adhesive can be efficiently cut with a commercially available auto glass tool. See the tool manufacturer's instructions for details.
  1. Remove these items:
  2. Remove the windshield molding (A) from the upper edge of the windshield (B). If necessary, cut the windshield molding with a utility knife.
    Fig 1: Identifying Windshield & Molding
    G08070542Courtesy of AMERICAN HONDA MOTOR CO., INC.
  3. If the original windshield will be reinstalled, make alignment marks across the windshield and the body with a grease pencil.
  4. Pull down the front area of the headliner (see HEADLINER REMOVAL/INSTALLATION ).
    NOTE: 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. Make a hole with an awl through the rubber dam and the adhesive 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.
  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 the adhesive (C) around the entire windshield.
    Fig 2: Identifying Windshield, Piano Wire & Rubber Dam
    G08070543Courtesy of AMERICAN HONDA MOTOR CO., INC.

    Cutting positions 

    Fig 3: Identifying Cutting Positions
    G08070544Courtesy of AMERICAN HONDA MOTOR CO., INC.
  7. Carefully remove the windshield.
  8. Scrape smooth the original 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 dams from the body.
  9. Clean the body bonding surface with a shop towel dampened with isopropyl alcohol. After cleaning, keep oil, grease, and water from getting on the clean surface.
  10. If you are reinstalling the original windshield, scrape off the original adhesive, the upper clips, and the rubber dams with a putty knife from the windshield. 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.
  11. Before installing a new windshield, attach a new rearview mirror harness cover base to the inside face of the windshield (see REARVIEW MIRROR HARNESS COVER BASE REPLACEMENT  ).
  12. Apply glass primer to the upper clip mounting areas on the windshield (C), and let it dry. Remove the adhesive backing and attach the rubber dam A, B and the upper clips (D) to the inside of the windshield as shown:
    • Make sure the rubber dams and the upper clips line up with the alignment marks (E).
    • Make sure the index tabs (F) on the clips face the left side.
    • Be careful not to touch the windshield where the adhesive will be applied.
      Fig 4: Identifying Windshield & Fasteners
      G08070545Courtesy of AMERICAN HONDA MOTOR CO., INC.
  13. Attach rubber dam C with adhesive tape to the inside surface of the windshield (A) as shown, using the edge of the black ceramic-coated area (B) as a guide:
    • Make sure the rubber dam lines up with the alignment marks (D).
    • Be careful not to touch the windshield where the adhesive will be applied.
      Fig 5: Identifying Windshield, Black Ceramic-Coated Area And Alignment Marks
      G08070546Courtesy of AMERICAN HONDA MOTOR CO., INC.
  14. Attach the windshield molding (A) with adhesive tape (B) to the upper edge of the windshield (C). Be careful not to touch the windshield where the adhesive will be applied.
    Fig 6: Identifying Windshield, Tape & Molding
    G08070547Courtesy of AMERICAN HONDA MOTOR CO., INC.
  15. Attach the molding upper seal (A) with adhesive tape to the inside surface of the windshield molding (B) as shown.
    Fig 7: Identifying Molding Upper Seal, Adhesive Tape & Windshield Molding
    G08070548Courtesy 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 the adhesive will be applied.
      Fig 8: Identifying Alignment Marks, Pins And Upper Clips
      G08070549Courtesy of AMERICAN HONDA MOTOR CO., INC.
  17. Remove the windshield.
  18. Apply a light coat of glass primer to the windshield (A) along the edge of the windshield molding (B) and the rubber dams (C) as shown, then lightly wipe it off with a gauze or a cheesecloth:
    • Apply glass primer to the molding.
    • Do not apply body primer to the windshield, and do not mix up the body and glass primer applicators.
    • 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 Windshield Primer Application Areas, Rubber Dams & Windshield Molding
      G08070550Courtesy of AMERICAN HONDA MOTOR CO., INC.
  19. 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 body primer dry for at least 10 minutes:
    • Do not apply body primer to any original adhesive on the flange.
    • Cover on the dashboard before applying the primer.
    • Be careful not to mix up the body and glass primer applicators.
    • Never touch the primed surfaces with your hands.
      Fig 10: Identifying Primer Application Areas
      G08070551Courtesy of AMERICAN HONDA MOTOR CO., INC.
  20. Cut a "V" in the end of the nozzle (A) on the adhesive cartridge as shown.
    Fig 11: Identifying Dimensions Of Nozzle On Adhesive Cartridge
    G08070552Courtesy of AMERICAN HONDA MOTOR CO., INC.
  21. Put the cartridge in a caulking gun, and run a continuous bead of the adhesive (A) on the windshield (B) along the edge of the windshield molding (C) and the rubber dams (D) as shown:
    • Apply the adhesive within 30 minutes after applying the glass primer.
    • Make a slightly thicker bead at each corner.
      Fig 12: Identifying Adhesive Application Areas
      G08070553Courtesy of AMERICAN HONDA MOTOR CO., INC.
  22. Hold the windshield over the opening with suction cups, align it with the alignment marks you 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. Remove the excess adhesive with a putty knife or a shop towel dampened with isopropyl alcohol.
  24. 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.
  25. Reinstall all remaining 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).
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