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Windshield Replacement

NOTE:
  • Put on gloves to protect your hands.
  • Wear eye protection while cutting the glass adhesive with a piano wire.
  • Use seat covers to avoid damaging the seats.
  • Glass adhesive can be efficiently cut with a commercially available auto glass tool. See the tool manufacturer's instructions for details.
  1. Remove these items:
  2. Remove the molding (A) from the upper edge of the windshield (B). If necessary, cut the molding with a utility knife.
    Fig 1: Identifying Windshield & Molding
    G05963116Courtesy of AMERICAN HONDA MOTOR CO., INC.
  3. If the old windshield is reinstalled, make alignment marks (A) across the glass and body with a grease pencil.
    Fig 2: Identifying Alignment Marks On Glass & Body
    G05963117Courtesy of AMERICAN HONDA MOTOR CO., INC.
  4. Pull down the front portion of the headliner (see HEADLINER REMOVAL/INSTALLATION ). Do not bend the headliner excessively, or you may crease or break it.
  5. Apply protective tape along the edge of the dashboard and body. Use an awl to punch a hole at an inside upper corner of the windshield through the rubber dam, adhesive, and the windshield upper seal. Push a piece of piano wire through the hole, and wrap each end around a piece of wood.
  6. With a helper on the outside, pull the piano wire (A) back and forth in a sawing motion. Hold the piano wire as close to the windshield (B) as possible to prevent damage to the body and dashboard.

    Carefully cut through the rubber dam and adhesive (C) around the entire windshield.

    Fig 3: Pulling Piano Wire Back & Forth In Sawing Motion
    G05963118Courtesy of AMERICAN HONDA MOTOR CO., INC.

    Cutting positions 

    Fig 4: Identifying Windshield (Cutting Positions)
    G05963119Courtesy of AMERICAN HONDA MOTOR CO., INC.
  7. Carefully remove the windshield.
  8. Scrape smooth the old adhesive with a knife until there is a thickness of about 2 mm (0.08 in.) on the bonding surface around the entire windshield opening flange:
    • Do not scrape down to the painted surface of the body; damaged paint will interfere with proper bonding.
    • Remove the rubber dam and fasteners from the body.
  9. Clean the body bonding surface with a sponge dampened in isopropyl alcohol. After cleaning, keep oil, grease and water from getting on the clean surface.
  10. If you are installing the old windshield, scrape old adhesive, the clips, the rubber dam, from the windshield with a putty knife. Clean the bonding surfaces on the inside face and the edge of the surfaces on the inside face and the edge of the windshield with isopropyl alcohol. Make sure the bonding surface is kept free of water, oil, and grease.
  11. Attach the rubber dams A, B and the upper clips (C) with adhesive tape to the inside face of the windshield (D) as shown:
    • Be sure the rubber dams and upper clips line up with the alignment marks (E).
    • Be careful not to touch the windshield where adhesive will be applied.
    Fig 5: Identifying Rubber Dams, Upper Clips & Windshield
    G05963120Courtesy of AMERICAN HONDA MOTOR CO., INC.
  12. Attach the dashboard seal (A) with adhesive tape to the inside surface of the windshield (B) as shown below.
    Fig 6: Identifying Dashboard Seal & Windshield
    G05963121Courtesy of AMERICAN HONDA MOTOR CO., INC.
  13. Attach the molding (A) with adhesive tape (B) to the upper edge of the windshield (C). Be careful not to touch the windshield where the adhesive will be applied.
    Fig 7: Identifying Windshield & Molding
    G05963122Courtesy of AMERICAN HONDA MOTOR CO., INC.
  14. Attach the molding upper seal (A) with adhesive tape to the inside surface of the molding (B) as shown below.
    Fig 8: Identifying Molding Upper Seal & Molding
    G05963123Courtesy of AMERICAN HONDA MOTOR CO., INC.
  15. Set the windshield in the opening, and center it. Make alignment marks (A) across the windshield and body with a grease pencil at the four points shown. Make sure both clips (B) contact with the edge of the body holes. Be careful not to touch the windshield where the adhesive will be applied.
    Fig 9: Identifying Windshield Alignment Area
    G05963124Courtesy of AMERICAN HONDA MOTOR CO., INC.
  16. Remove the windshield.
  17. With a sponge, apply a light coat of glass primer around the edge of the windshield (A) between the dams (B, C) and molding (D) as shown below, then lightly wipe it off with gauze or cheesecloth:
    • Apply glass primer to the molding.
    • Do not apply body primer to the windshield, and do not get body and glass primer sponges mixed up.
    • Never touch the primed surfaces with your hands. If you do, the adhesive may not bond to the windshield properly, causing a leak after the windshield is installed.
    • Keep water, dust, and abrasive materials away from primed surfaces.
    Fig 10: View Of Windshield Glass Primer Area
    G05963125Courtesy of AMERICAN HONDA MOTOR CO., INC.
  18. With a sponge carefully apply a light coat of body primer to any exposed paint or metal around the flange where new adhesive will be applied. Let the primer dry for at least 10 minutes:
    • Do not apply body primer to any remaining original adhesive on the flange.
    • Be careful not to mix up the body and glass primer sponges.
    • Never touch the primed surfaces with your hands.
    Fig 11: Identifying Windshield Glass Primer Area
    G05963126Courtesy of AMERICAN HONDA MOTOR CO., INC.
  19. Cut a "V" in the end of the nozzle (A) on the adhesive cartridge as shown below.
    Fig 12: Identifying Nozzle Dimension
    G05963127Courtesy of AMERICAN HONDA MOTOR CO., INC.
  20. Put the cartridge in a caulking gun, and run a continuous bead of adhesive (A) around the edge of the windshield (B) between the dam (C) and the molding (D) as shown below. Apply the adhesive within 30 minutes after applying the glass primer. Make a slightly thicker bead at each corner.
    Fig 13: Identifying Windshield Dam & Molding
    G05963128Courtesy of AMERICAN HONDA MOTOR CO., INC.
  21. Hold the windshield with suction cups to over the opening, align it with the alignment marks made in step 15, and set it down on the adhesive. Lightly push on the windshield until its edges are fully seated on the adhesive all the way around.
    NOTE: Do not open or close the doors for about an hour until the adhesive is dry.
  22. Remove the excessive adhesive with a putty knife or a shop towel dampened with isopropyl alcohol.
  23. Wait at least an hour for the adhesive to dry, then spray water over the windshield and check for leaks. Mark leaking areas, and let the windshield dry, then seal with sealant. Let the vehicle stand for at least 4 hours after windshield installation. If the vehicle has to be used with the first 4 hours, it must be driven slowly.
  24. Reinstall all remaining removed parts.
    NOTE: Advise the customer not to do the following things for 2 to 3 days:
    • Slam the doors with all the windows rolled up.
    • Twist the body excessively (such as when going in and out of driveways at an angle or driving over rough, uneven roads).
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