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Windshield Glass: Installation

CAUTION:
  • After installing the urethane installed glass, the vehicle should not be driven until the urethane has cured. The curing time for temperatures above 13°C (55°F) and relative humidity above 50% is 12-24 hours. (See Drive Away chart for cure times as temperature and humidity vary). Inadequate curing of the urethane may adversely affect the strength of the urethane bond.
CAUTION:
  • Open the windows to prevent the windshield glass from being pushed out by air pressure if doors are closed.
  1. Dry fit the windshield. Make alignment marks with tape or non-staining pencil.
    CAUTION:
    • Do not scratch pinch weld area.
  2. Trim the remaining urethane adhesive on the pinch weld to within specification. The surface should be smooth and free of cuts and contamination.
  3. Use the wool applicator to apply metal primer to any exposed metal on the pinch weld. Allow six to ten minutes to dry.
  4. If reinstalling the original windshield, remove excess urethane adhesive from the windshield glass
  5. Clean the inside of the glass surface with an alcohol-free cleaner making sure the ceramic-coated area is clean.
    CAUTION:
    • Wipe off urethane glass prep immediately after each application because it flash dries.
  6. If installing a new windshield, apply glass prep twice around the glass surface.
  7. If installing a new windshield, apply glass primer to the same area that was prepped in the previous step. Allow five minutes to dry.
    Fig 1: Applying Glass Primer
    G03727476Courtesy of MAZDA MOTORS CORP.
  8. Apply foam dam to the bottom of the windshield glass.
    Fig 2: Applying Foam Dam To Bottom Of Windshield Glass
    G03727477Courtesy of MAZDA MOTORS CORP.
  9. Cut the urethane applicator tip to specification.
    Fig 3: Cutting Urethane Applicator Tip
    G03727478Courtesy of MAZDA MOTORS CORP.
  10. Apply a bead of urethane adhesive to the sides and top of the windshield glass.
    Fig 4: Identifying Urethane Adhesive Dimensions At Top Of Windshield Glass
    G03727479Courtesy of MAZDA MOTORS CORP.
  11. Apply a bead of urethane adhesive to the bottom of the windshield glass outside the foam dam.
    Fig 5: Identifying Urethane Adhesive Dimensions At Windshield Glass Outside Foam Dam
    G03727480Courtesy of MAZDA MOTORS CORP.
  12. Install the windshield by aligning it to the marks previously made.
    CAUTION:
    • Carry out this step after the urethane has cured.
  13. Check the windshield glass installation for air or water leaks through the urethane seal.
  14. If necessary, remove excess urethane adhesive from the outside surface of the windshield glass.
  15. Install the cowl grille. See COWL PANEL GRILLE
  16. Reposition the front portion of the headliner.
  17. Install the overhead console.
    1. Position the overhead console. If equipped, connect the electrical connector.
    2. Install the screws.
    Fig 6: Installing Overhead Console
    G03727481Courtesy of MAZDA MOTORS CORP.
  18. Install the two sunvisor clips
    1. Position the sun visors and clips.
    2. Install the six screws.
    Fig 7: Installing Sunvisor Clips
    G03727482Courtesy of MAZDA MOTORS CORP.
  19. Install the rear view mirror.
  20. Install the two windshield side garnish moldings.
    Fig 8: Installing Windshield Side Garnish Moldings
    G03727483Courtesy of MAZDA MOTORS CORP.
  21. Install the two A - pillar passenger assist handles.
    1. Position the two assist handles.
    2. Install the four bolts.
    3. Close the four assist handle covers.
  22. Install the driver and passenger assist handles.
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