Windshield Installation

WARNING:

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

CAUTION:

If a door is opened or closed when all the window glass is closed, the resulting change in air pressure could cause the sealant to crack preventing the proper installation of the glass. Keep the door glass opened until the windshield installation is completed.
On vehicles with the auto wiper system, when the ignition switch is turned to the ON position after replacing the rain sensor with a new one, the windshield condition is verified and the initial setting is stored. Before installing a rain sensor, always remove water or dirt from the windshield. Perform the initial setting again in the following cases: See RAIN SENSOR REINITIALIZATION SETTING .
- The windshield is replaced and the rain sensor is reused.
- The auto wiper system operates incorrectly.

Remove the sealant along the perimeter of the glass using a cutting a razor. (When reusing the glass)
Clean and degrease an approx. 50 mm {1.97 in} wide strip along the perimeter of the windshield.
If the existing windshield is to be reinstalled, attach the dam along the ceramic voids.
Inspect the glass for cracks. If it is cracked, chamfer it using sandpaper.

Fig 1: Identifying Dam Cut Point
Courtesy of MAZDA MOTORS CORP.
Align the marks made before removal and install the pin to the windshield referring to the figure, (when reusing the glass, and the pin was removed)
Install the windshield molding.

Fig 2: Identifying Hollowed Mark In Ceramic Coating
Courtesy of MAZDA MOTORS CORP.
Use glass primer on the glass, then allow it to dry for approx. 30 min.
CAUTION:
- To prevent weakening of the primer adhesion, keep the bonding surface free of dirt, moisture, and grease. Do not touch the surface with your hand.
NOTE:
- Make sure to apply primer to the hollowed marks in the ceramic coating.
  
  Fig 3: Identifying Primer Applying Area
  Courtesy of MAZDA MOTORS CORP.
Cut away the old sealant using a razor or scraper so that 1-2 mm {0.04-0.07 in} thickness of sealant remains along the perimeter of the frame.
If the sealant has come off completely in any one place, apply some primer after degreasing, and allow it approx. 30 min to dry. Then apply 2 mm {0.08 in} thickness of new sealant.
CAUTION:
- To prevent weakening of the primer adhesion, keep the bonding surface free of dirt, moisture, and grease. Do not touch the surface with your hand.
Clean and degrease along the perimeter of the bonding area on the body.

Fig 4: Cutting Old Sealant With Razor
Courtesy of MAZDA MOTORS CORP.
Apply body primer on the body as shown in the figure, then allow it to dry for approx. 30 min.
CAUTION:
- To prevent weakening of the primer adhesion, keep the bonding surface free of dirt, moisture, and grease. Do not touch the surface with your hand.
NOTE:
- Apply primer to the hollowed marks in the ceramic coating.
  
  Fig 5: Identifying Primer Application Area With Specifications
  Courtesy of MAZDA MOTORS CORP.
Apply sealant to the area of the glass surface as shown in the figure.
Insert the windshield locator pins to the body and install the windshield.

Fig 6: Applying Sealant To Area Of Glass Surface
Courtesy of MAZDA MOTORS CORP.
Verify that the clearance of the A-pillar is within the range shown in the figure, and press along the perimeter of the glass.
Install the headliner.
Install the following parts:
1. Assist handle. See ASSIST HANDLE REMOVAL/INSTALLATION .
2. A-pillar trim. See A-PILLAR TRIM REMOVAL/INSTALLATION .
3. Map light. See FRONT MAP LIGHT REMOVAL/INSTALLATION .
4. Sunvisor. See SUNVISOR REMOVAL/INSTALLATION .
5. Rearview mirror. See REARVIEW MIRROR INSTALLATION [VEHICLES WITH AUTO LIGHT/WIPER SYSTEM] . See REARVIEW MIRROR INSTALLATION [VEHICLES WITHOUT AUTO LIGHT/WIPER SYSTEM] )
  
  Fig 7: Identifying Clearance Of A-Pillar With Specifications
  Courtesy of MAZDA MOTORS CORP.
6. Rain sensor (Vehicles with auto light/wiper system). See RAIN SENSOR REMOVAL/INSTALLATION )
7. Cowl grille. See COWL GRILLE REMOVAL/INSTALLATION .
8. Windshield wiper arm and blade. See WINDSHIELD WIPER ARM AND BLADE REMOVAL/INSTALLATION .
Allow the sealant to harden completely.
Sealant hardening time: 24 h