Windshield Installation

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 along the perimeter of the frame.
WARNING:
- Using a razor with bare hands can cause injury. Always wear gloves when using a razor.
  
  Fig 1: Cutting Away Old Sealant Using Razor
  Courtesy of MAZDA MOTORS CORP.
If the sealant has come off completely in any one place, apply some primer after degreasing, and allow it approximately 30 minutes to dry. Then put on new sealant to create a 2 mm {0.08 in} layer.
Clean and degrease an approximately 50.0 mm {1.97 in} wide strip along the perimeter of the glass and the bonding area on the body.
If installing reused glass, install pins at the ceramic void on the upper part of the windshield.

Fig 2: Installing Pins At Ceramic Void On Upper Part Of Windshield
Courtesy of MAZDA MOTORS CORP.
If installing reused glass, align the windshield molding marking and the center of the upper section of the windshield, then install the molding to the windshield.
Use only glass primer on the glass. Allow it to dry for approximately 30 minutes .
CAUTION:
- Keep the area free of dirt and grease, and do not touch the surface. Otherwise, the primer may not properly bond to the surface of the glass and body, which may cause leaks to occur.
  
  Fig 3: Identifying Primer Application Area
  Courtesy of MAZDA MOTORS CORP.
Apply sealant to the area of the glass surface as shown in the figure.

Fig 4: Applying Sealant To Area Of Glass Surface
Courtesy of MAZDA MOTORS CORP.
Set the windshield in place and insert the pins into the body. Install the windshield.
Verify that the gap of the A-pillar part as shown in the figure.

Fig 5: Verifying Gap Of A-Pillar Part
Courtesy of MAZDA MOTORS CORP.
Keeping the measurement of the molding lip gap within specification, press completely along the perimeter of the glass.

Fig 6: Molding Lip Gap Specifications
Courtesy of MAZDA MOTORS CORP.
Install the cowl grille.
Install the headliner
Install the rearview mirror.
Allow the sealant to harden completely.
Sealant hardening time: 24 hours