Windshield Installation

CAUTION:

To prevent the sealant from cracking or the glass from being pushed out by air pressure if a door is closed, open all of the windows and leave them open until the sealant has hardened.

Cut away the old sealant using a razor so that 1-2 mm (0.04-0.07 in) thickness of sealant remains around the circumference of the frame.
- If all the sealant has come off in any one place, apply some primer after degreasing, and allow it 30 minutes to dry. Then put on new sealant to create 2 mm (0.08 in) layer.
WARNING:
- Using a razor with bare hands can cause injury. Always wear gloves when using a razor.
Clean and degrease an approximately 50.0 mm (1.97 in) wide strip around the circumference of the glass and the bonding area on the body.

Fig 1: Cutting Away Old Sealant
Courtesy of MAZDA MOTORS CORP.
Securely bond a dam along the circumference of the glass 8.0 mm (0.31 in) from the edge.

Fig 2: Bonding Dam Along Circumference Of Glass
Courtesy of MAZDA MOTORS CORP.
Install the spacers B on the glass as shown.

Fig 3: Installing Spacers "B" On Glass
Courtesy of MAZDA MOTORS CORP.
Install spacers A into the hole.
Temporarily install the glass onto the body and adjust the glass-to-body clearance.
Make a mark on the glass directly above the V-notch of spacers A.
Verify that the gap along the upper edge is 7.3 mm (0.29 in), and that the side edge is 6.8 mm (0.27 in).
Remove the windshield.

Fig 4: Installing Spacers "A" Into Hole
Courtesy of MAZDA MOTORS CORP.
Install the fasteners on the glass marks as shown.

Fig 5: Installing Fasteners On Glass
Courtesy of MAZDA MOTORS CORP.
Install the fasteners on the body as shown.

Fig 6: Installing Fasteners On Body
Courtesy of MAZDA MOTORS CORP.
Use a brush to apply primer to the bonding area of the glass, the body, and the molding within the area shown.
CAUTION:
- Keep the area free of dirt and grease, and do not touch the surface, otherwise the primer may not properly bond to the surface of the glass and body, which may cause leaks to occur.
NOTE:
- Use only glass primer on the glass, and body primer on the body and the molding.
  Allow it to dry for approximately 30 minutes.
Fig 7: Identifying Bonding Area Of Glass To Apply Primer
Courtesy of MAZDA MOTORS CORP.
Once the primer is dry, apply sealant around the entire circumference to fill the gap between the dam and the edge of the glass measuring 11.0 mm (0.433 in) high and 5.0 mm (0.20 in) wide.
Align the glass marks with the V-notches in the spacers and install the glass onto the body.
Press firmly inward on the glass to compress the sealant.

Fig 8: Identifying Area To Apply Sealant
Courtesy of MAZDA MOTORS CORP.
Verify that the gap along the upper edge is 7.3 mm (0.29 in) and side edge is 6.8 mm (0.27 in).

Fig 9: Identifying Gap Along Upper Edge And Side Edge
Courtesy of MAZDA MOTORS CORP.
Use a scraper to smooth away any sealant that oozes out. Add more sealant to any points of poor contact. Adjust the sealant as shown if necessary.
Before the surface of the sealant has hardened, install the windshield molding.

Fig 10: Hardening Time Of Sealant
Courtesy of MAZDA MOTORS CORP.

Fig 11: Adjusting Sealant
Courtesy of MAZDA MOTORS CORP.
Align the marking on the molding with the inner side of the body groove. (1)
Install the upper edge starting from the outer ends and moving inward. (2)
Install the corners. (3)
Install the windshield molding installation clips to the cowl grille hole. (4)
Install the sides, starting from the upper edge and moving downward, being careful not to pull out the corners. (5)
Use isopropyl alcohol to remove any excess sealant.
Install the headliner. (See HEADLINER REMOVAL/INSTALLATION .)
Install the cowl grille. (See COWL GRILLE REMOVAL/INSTALLATION .)
Install the base. (See BASE INSTALLATION .)
Install the rearview mirror. (See REARVIEW MIRROR INSTALLATION .)

Fig 12: Identifying Align Mark On Molding
Courtesy of MAZDA MOTORS CORP.