Mazda Protege 5. Manual — part 316

GLASS/WINDOWS/MIRRORS

09–12–19

09–12

10. Verify that the gap along the upper, side and

lower edge is 8.8 mm {0.35 in}.

11. Press firmly inward on the glass to compress the

sealant.

Hardening time of sealant

12. Install the rear spoiler.
13. Install the liftgate trim.

End Of Sie

WINDSHIELD REMOVAL

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1. Remove the rearview mirror. (See 09–12–30 REARVIEW MIRROR REMOVAL.)
2. Remove the cowl grille. (See 09–16–1 COWL GRILLE REMOVAL/INSTALLATION.)
3. Remove the headliner. (See 09–17–16 HEADLINER REMOVAL/INSTALLATION.)
4. Apply protective tape along the edge of the body to protect it from damage.
5. Apply protective tape to the dashboard to protect it from damage.
6. Cut the lip of the windshield molding using a

razor.

Warning

••••

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

Note

•

The windshield molding is a replacement
part.

Not Reusing Windshield

1. Remove the base. (See 09–12–31 BASE REMOVAL.)

Temperature

Surface

hardening time

Time required

until car can be
put into service

5

°

C {41

°

F}

Approx. 1.5 h

Approx. 12 h

20

°

C {68

°

F}

Approx. 1 h

Approx. 4 h

35

°

C {95

°

F}

Approx. 10 min.

Approx. 2 h

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GLASS/WINDOWS/MIRRORS

09–12–20

2. Use a tool like that shown in the figure, and insert

the blade into the sealant.

Note

•

For the areas of the sealant that are difficult
to cut, use the SST (piano wire) and follow
the procedures under “Reusing Windshield”.

3. Pull through the sealant around the edge of the

glass.

4. Remove the glass.

Reusing Windshield

Note

•

Before removing the windshield from the body, mark the position of the windshield by affixing tape to the
windshield and body panel.

1. Make a hole through the sealant except fasteners

and spacers from the inside of the vehicle using
an awl.

2. Pass the SST (piano wire) through the hole.

Warning

••••

Using a SST (piano wire) with bare hands
can cause injury. Always wear gloves
when using a SST (piano wire).

3. Wind each end of the SST (piano wire) around a

bar.

4. Working with another person, saw through the

sealant around the edge of the glass.

Note

•

Use a long sawing action to spread the work
over the whole length of the SST (piano
wire) to prevent it from breaking.

5. Remove the windshield.

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GLASS/WINDOWS/MIRRORS

09–12–21

09–12

6. Remove the dam from the windshield.
7. Remove the fasteners.
8. Remove spacers A and B.

End Of Sie

WINDSHIELD INSTALLATION

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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.

1. Cut away the old sealant using a razor so that 1—2 mm {0.04—0.07 in} thickness of sealant remains around

the circumference of the frame.

•

If all the sealant has come off in any one place, apply some primer after degreasing, and allow it 30
minutes to dry. Then put on new sealant to create 2 mm {0.08 in} layer.

Warning

••••

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

2. Clean and degrease an approximately 50.0 mm

{1.97 in} wide strip around the circumference of
the glass and the bonding area on the body.

3. Securely bond a dam along the circumference of

the glass 8.0 mm {0.31 in} from the edge.

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GLASS/WINDOWS/MIRRORS

09–12–22

4. Install the spacers B on the glass as shown.

5. Install spacers A into the hole.
6. Temporarily install the glass onto the body and

adjust the glass-to-body clearance.

7. Make a mark on the glass directly above the V-

notch of spacers A.

8. Verify that the gap along the upper edge is

7.3 mm {0.29 in}, and that the side edge is 6.8
mm {0.27 in}.

9. Remove the windshield.

10. Install the fasteners on the glass marks as shown.

11. Install the fasteners on the body as shown.

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