2012 Honda Insight BaseFACTORY OEM SERVICE PROCEDURE

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 windshield molding (A) from the edge of the windshield (B), If necessary, cut the windshield molding with a utility knife.
    Fig 1: Removing Windshield Molding From Edge Of Windshield
    G08093961Courtesy of AMERICAN HONDA MOTOR CO., INC.
  3. If the old windshield will be reinstalled, make alignment marks across the windshield and the body with a grease pencil.
  4. Pull down the front area of the headliner (see HEADLINER REMOVAL/INSTALLATION ). Take care not to bend the headliner excessively, or you may crease or break it.
  5. Apply protective tape along the edge of the dashboard and the body. Make a hole with an awl through the rubber dam and the adhesive from Inside the vehicle at a corner of the windshield. 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 the adhesive (C) around the entire windshield.
    Fig 2: Pulling Piano Wire Back And Forth In Sawing Motion
    G08093962Courtesy of AMERICAN HONDA MOTOR CO., INC.

    Cutting positions 

    Fig 3: Identifying Cutting Positions
    G08093963Courtesy 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 dams and the upper clips from the body.
  9. Clean the body bonding surface with a shop towel dampened in isopropyl alcohol. After cleaning, keep oil, grease, and water from getting on the clean surface.
  10. If you are reinstalling the old windshield, scrape off all of the old adhesive, the upper clips and the rubber dams from the windshield with a putty knife. Clean the bonding 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. Apply glass primer to the upper clips mounting areas on the windshield (B), and let it dry. Remove the adhesive backing and attach the rubber dams A, rubber dam (D), rubber dams C and the upper clips (E) to the inside of the windshield as shown:
    • Make sure the rubber dams and the upper clips line up with the alignment marks (F).
    • Be careful not to touch the windshield where adhesive will be applied.
      Fig 4: Identifying Windshield, Rubber Dams, Upper Clips And Alignment Marks
      G08093964Courtesy of AMERICAN HONDA MOTOR CO., INC.
  12. Attach a new windshield molding (A) with adhesive tape (B) to the edge of the windshield (C):
    • Make sure each corner of the molding lines up with the ones of the windshield.
    • Be careful not to touch the windshield where adhesive will be applied.
      Fig 5: Attaching Windshield Molding With Adhesive Tape To Edge Of Windshield
      G08093965Courtesy of AMERICAN HONDA MOTOR CO., INC.
  13. Set the windshield (A) in the opening, and center it. Make alignment marks (B) across the windshield and the body with a grease pencil at the four points shown. Make sure the upper clips (C) contact with the edge of the body holes. Be careful not to touch the windshield where adhesive will be applied.
    Fig 6: Identifying Alignment Marks On Windshield And Body With Grease Pencil At Four Points
    G08093966Courtesy of AMERICAN HONDA MOTOR CO., INC.
  14. Remove the windshield.
  15. Apply a light coat of glass primer to the windshield (A) along the edge of the windshield molding (B) and the rubber dams (C) as shown, then lightly wipe it off with gauze or cheesecloth:
    • With the printed dots (D) on the windshield as a guide, apply glass primer to the bottom (E) of the windshield.
    • Apply glass primer to the molding.
    • Do not apply body primer to the windshield, and do not mix up the body primer applicators and the glass primer applicators.
    • 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 the primed surface.
      Fig 7: Applying Light Coat Of Glass Primer To Windshield Along Edge Of Windshield Molding And Rubber Dams
      G08093967Courtesy of AMERICAN HONDA MOTOR CO., INC.
  16. Carefully apply a light coat of body primer to any exposed paint or metal around the flange where the new adhesive will be applied. Let the body 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 primer applicators and the glass primer applicators.
    • Never touch the primed surfaces with your hands.
    • Cover the dashboard before applying the primer.
      Fig 8: Applying Light Coat Of Body Primer To Any Exposed Paint
      G08093968Courtesy of AMERICAN HONDA MOTOR CO., INC.
  17. Cut a "V" in the end of the nozzle (A) on the adhesive cartridge as shown.
    Fig 9: Identifying Adhesive Cartridge Nozzle End Cut Dimensions
    G08093969Courtesy of AMERICAN HONDA MOTOR CO., INC.
  18. Put the cartridge in a caulking gun, and run a continuous bead of adhesive (A) around the windshield (B) along the edge of the rubber dams (C) and the windshield molding (D) as shown:
    NOTE:
    • Apply the adhesive within 30 minutes after applying the glass primer. Make a slightly thicker bead at each corner.
    • Apply glass primer to the bottom (E) of the windshield.
    • Apply glass primer to the molding.
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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.

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