For 1990-2009 cars

### Removal Procedure

Caution: When working with any type of glass or sheet metal with exposed or rough edges, wear approved safety glasses and gloves in order to reduce the chance of personal injury.

1. Remove the air inlet grille from the vehicle. Refer to Air Inlet Grille Panel Replacement in Body Front End.
2. Tape the body surface around the window in order to prevent damage.
3. Remove the inside rearview mirror from the vehicle. Refer to Inside Rearview Mirror Replacement .
4. Pull the windshield reveal molding (1) from the windshield (5).
5. Remove the windshield reveal molding (1) from the vehicle.
6. Remove 1 screw from each windshield stopper (1).
7. Remove the stoppers (1) from the vehicle.
8. Punch a hole through the adhesive with an eyeletter between the windshield side pillar (1) and the window (2).
9. Slip piano wire through the hole.
10. Twist the ends of the piano wire (1) around the wood dowels.
11. With a second technician, cut the adhesive all around the windshield (2) with the piano wire (1).
12. Remove the windshield (2) from the vehicle.
13. Remove the rubber dam from the windshield opening.
14. Clean a knife with alcohol or petroleum distillate in order to remove any dirt or oil.
15. Use the knife in order to trim the remaining adhesive (2) to a uniform thickness.
16. Clean any loose material from the windshield opening.
17. If you are reusing the windshield, remove all urethane from the windshield.

### Installation Procedure

1. Clean around the edge of the inside surface of the window where adhesive will be applied with a clean, alcohol-dampened cloth.

Allow the cleaned surface to air dry for ten minutes.

2. Install the 2 windshield stoppers (1) to the vehicle. Secure each windshield stopper (1) with 1 screw.
3. Peel paper from one side of the new windshield spacer (1).
4. Attach the windshield spacer (1) to the windshield.
5. Place the windshield to the body of the vehicle.
6. Position the window so that the distance between the body and the windshield are even.
7. Use a wax pencil in order to mark mating points (1) on the windshield and the body.
8. Remove the windshield (2).

Important:

• | Refer to the manufacturer's instructions and warnings for proper handling instructions and drying time.

• | Do not touch the primer-coated surface.

• | Shake the primer before opening in order to ensure proper mixing.

9. Use a new brush in order to apply primer #1 (2) to the edge and inner surface of the windshield (1).
10. Use a new brush in order to apply primer #2 (2) to the edge and inner surface of the windshield (1).

Important:

• | Start applying the adhesive from the bottom side of the windshield.

• | Do not damage the primer.

• | Apply the adhesive 16-17 mm (0.63-0.69 inches) to the upper left and right sides of the windshield.

• | Apply the adhesive 24-25 mm (0.94-0.98 inches) to the bottom of the windshield.

11. Use a cartrige-type caulking gun in order to apply a smooth continuous bead of urethane adhesive around the edge of the windshield.
12. With the help of an assistant, use rubber suction cups in order to install the windshield in alignment with the mating marks.
13. Firmly press the window in order to set the adhesive.
14. Avoid excessive adhesive flash which would cause an appearance problem.
15. In order to ensure a watertight seal, use a small disposable brush or a flat-bladed tool in order to paddle the material around the edge of the window.
16. Apply more adhesive to the underfilled parts, as needed.
17. Wipe away any excess adhesive.
18. Warm the molding for half of an hour at 35°C (95°F) in order to facilitate installation of the molding.
19. Fit the new reveal molding onto the windshield.
20. Use a soft spray of water in order to watertest the windshield immediately after installation.
21. Do not direct a hard stream of high-pressure water at the fresh adhesive material.
22. If any leaks are found, use the following procedure in order to repair the leaks:

22.1. | Dry the window

22.2. | Use a plastic paddle or a flat-bladed tool in order to paddle in extra adhesive at the leak point.

22.3. | If the leak persists, remove the window in order to repeat the entire installation process.

23. Install the air inlet grille to the vehicle. Refer to Air Inlet Grille Panel Replacement in Body Front End.
24. Install the inside rearview mirror to the vehicle. Refer to Inside Rearview Mirror Replacement .

Important:

• | Do not drive the vehicle until the adhesive is set.

• | Do not use compressed air, heat, or infrared light in order to accelerate the drying time.

• | Allow the adhesive to dry normally.

• | Do not slam the vehicle doors before the adhesive sets.

| Slamming the doors may cause the windshield to shift or become loose.

25. Applying water to the adhesive will speed the cure of the urethane.