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Windshield Installation

WARNING: This page is about a different car, the 2005 Mazda RX-8. However, it is still accessible from the selected car via links, so may be relevant.
WARNING:
  • Using a razor with bare hands can cause injury. Always wear gloves when using a razor.
CAUTION:
  • Proper installation of the windshield may be difficult if sealant is cracked or the glass is pushed out by air pressure when a door is opened/closed with all the window glass closed. Leave all the windows open until the windshield is installed completely.
  1. Cut away the old sealant using a razor so that a 1-2 mm {0.04-0.07 in}  thickness of sealant remains along the perimeter of the frame.
    2. Fig 1: Cutting Away The Old Sealant Using Razor
    G03703047Courtesy of MAZDA MOTORS CORP.
  2. If the sealant has come off completely in any one place, apply some primer after degreasing, and allow it to dry for approx. 30 min.  Then apply a 2 mm {0.08 in}  thickness of sealant.
  3. Clean and degrease an approx. 50 mm {2.0 in}  wide strip along the perimeter of the windshield and the bonding area on the body.
  4. If installing a reused windshield, perform the following procedure:
    1. Attach the pins to the seating positions where marked during removal.
    2. Install the windshield molding.
      3. Fig 2: Installing The Windshield Molding
      G03703048Courtesy of MAZDA MOTORS CORP.
  5. Use only glass primer on the glass, and body primer on the body and the molding, then allow it to dry for approx. 30 min. 
    CAUTION:
    • Keep the area free of dirt, water and grease, and do not touch the surface. Otherwise, the primer may not properly bond to the surface of the glass and body, causing leaks to occur.
      • Fig 3: Applying Primer On Glass
      G03703049Courtesy of MAZDA MOTORS CORP.
  6. Apply sealant to the glass surface as shown in the figure.
    7. Fig 4: Applying Sealant To The Glass Surface
    G03703050Courtesy of MAZDA MOTORS CORP.
  7. Insert the positioning pins to the body, then install the windshield.
  8. Press the windshield pins to engage the tabs to the body.
  9. Press completely along the perimeter of the glass so that the measurement of the molding lip gap is within specification.
    Fig 5: Pressing The Windshield Pins
    G03703051Courtesy of MAZDA MOTORS CORP.
    Fig 6: Pressing Completely Along The Perimeter Of The Glass
    G03703052Courtesy of MAZDA MOTORS CORP.
  10. Install the following parts:
    1. Map light (See MAP LIGHT REMOVAL/INSTALLATION .)
    2. Sunvisor (See SUNVISOR REMOVAL/INSTALLATION .)
    3. A-pillar trim (See A-PILLAR TRIM REMOVAL/INSTALLATION .)
    4. Rearview mirror (See REARVIEW MIRROR REMOVAL/INSTALLATION .)
    5. Cowl grille (See COWL GRILLE REMOVAL/INSTALLATION .)
    6. Windshield wiper arm and blade (See WINDSHIELD WIPER ARM AND BLADE REMOVAL/INSTALLATION .)
  11. Allow the sealant to harden completely.

    Sealant hardening time: 24 h 

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