Windshield Installation

WARNING:

Using a razor with bare hands can cause injury. Always wear gloves when using a razor.

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.
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 8.5 mm {0.33 in} from the edge.

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

Fig 3: Installing Fasteners On Glass Marks
Courtesy of MAZDA MOTORS CORP.
Align the front windshield molding with the edge of the glass. (1)
Install the front windshield molding in the direction shown by the arrow. (2)

Fig 4: Aligning Front Windshield Molding With Edge Of Glass
Courtesy of MAZDA MOTORS CORP.
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.
Remove the windshield.

Fig 5: Marking On Glass Directly Above V-Notch Of Spacers
Courtesy of MAZDA MOTORS CORP.
Paste the fasteners on the body as shown.
CAUTION:
- Keep the area free of dirt and grease, and do not touch the surface or the primer may not properly bond to the surface of the glass and body, which may cause leaks to occur.
Fig 6: Pasting 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 region shown.
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: Locating Boding Area For Primer Application
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 {0.43 in} high and 5.0 mm {0.20 in} wide.

Fig 8: Applying Sealant Around Entire Circumference
Courtesy of MAZDA MOTORS CORP.
Align the glass marks with the V-notches in spacers and install the glass onto the body.
Press firmly inward on the glass to compress the sealant.
Verify that the gap along the upper edge is 4.9 mm {0.19 in} and side edge is 4.4 mm {0.17 in} .

Fig 9: Aligning Glass Marks With V-Notches In Spacers
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.

HARDENING TIME OF SEALANT

Temperature	Surface Hardening Time	Time Required Until Car Can Be Put Into Service
5 °C {41 °F}	Approx. 1.5 h	Approx. 12 h
20 °C {68 °F}	Approx. 1 h	Approx. 4 h
35 °C {95 °F}	Approx. 10 min.	Approx. 2 h

Fig 10: Locating Area For Adjusting Sealant

Courtesy of MAZDA MOTORS CORP.

Use isopropyl alcohol to remove any excess sealant.
Install the headliner. (See HEADLINER REMOVAL/INSTALLATION .)
Install the cowl grille.
Install the base. (See BASE INSTALLATION .)
Install the rearview mirror. (See REARVIEW MIRROR INSTALLATION .)