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.
Securely bond a dam along the circumference of the glass 7.0 mm {0.28 in} from the edge.
Install spacers into the hole.
Temporarily install the glass onto the body and adjust the glass-to-body clearance.

Fig 1: Bonding Dam Along Circumference Of Glass From Edge
Courtesy of MAZDA MOTORS CORP.
Make a mark on the glass directly above the V-notch of spacers.
Remove the windshield.
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 2: Making Mark On Glass Directly Above V-Notch Of Spacers
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 3: Locating Areas For Primer Application
Courtesy of MAZDA MOTORS CORP.
Align the edge of the protector to the spot mark.
Securely bond the protector to the body as indicated in the figure.

Fig 4: Aligning Edge Of Protector To Spot Mark
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.
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.

Fig 5: Applying Sealant Around Entire Circumference To Fill Gap Between Dam & Edge Of Glass
Courtesy of MAZDA MOTORS CORP.
Verify that the gap along the upper edge is 8.0 mm {0.31 in} and side edge is 7.0 mm {0.28 in}.

Fig 6: Measuring Gap Along Upper Edge & 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. (See WINDSHIELD MOLDING INSTALLATION .)

Fig 7: Locating Areas For Sealant Adjustment

Courtesy of MAZDA MOTORS CORP.

HARDENING TIME OF SEALANT

Temperature	Surface hardening time	Time required until vehicle can be put into service
5°C{41°F}	Approx. 1.5 hr	Approx. 12 hr
20°C{68°F}	Approx. 1 hr	Approx. 4 hr
35°C{95°F}	Approx. 10 min.	Approx. 2 hr

Use isopropyl alcohol to remove any excess sealant.
Install the front header trim. (See FRONT HEADER TRIM REMOVAL/INSTALLATION .)
Install the striker. (See CONVERTIBLE TOP DISASSEMBLY/ASSEMBLY .) (See DETACHABLE HARDTOP DISASSEMBLY/ASSEMBLY .)
Install the cowl grille. (See COWL GRILLE REMOVAL/INSTALLATION .)
Install the A-pillar trim. (See A-PILLAR TRIM REMOVAL/INSTALLATION
Install the base. (See BASE INSTALLATION .)
Install the rearview mirror. (See REARVIEW MIRROR INSTALLATION .)