2003 Mazda Protege5 AutomaticFACTORY OEM SERVICE PROCEDURE

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.
  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.
    Fig 1: Cutting Away Old Sealant
    G01915070Courtesy of MAZDA MOTORS CORP.
  3. Securely bond a dam along the circumference of the glass 8.0 mm (0.31 in)  from the edge.
    Fig 2: Bonding Dam Along Circumference Of Glass
    G01915071Courtesy of MAZDA MOTORS CORP.
  4. Install the spacers B on the glass as shown.
    Fig 3: Installing Spacers "B" On Glass
    G01915072Courtesy of MAZDA MOTORS CORP.
  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.
    Fig 4: Installing Spacers "A" Into Hole
    G01915073Courtesy of MAZDA MOTORS CORP.
  10. Install the fasteners on the glass marks as shown.
    Fig 5: Installing Fasteners On Glass
    G01915074Courtesy of MAZDA MOTORS CORP.
  11. Install the fasteners on the body as shown.
    Fig 6: Installing Fasteners On Body
    G01915075Courtesy of MAZDA MOTORS CORP.
  12. Use a brush to apply primer to the bonding area of the glass, the body, and the molding within the area shown.
    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.
Factory Service Tools

Use the Manual With the Right Hardware

Pair factory procedures with proven DIY tools so the instructions are easier to execute.

Disclosure: Verified tool recommendations may earn an affiliate commission at no cost to you.

Shop Manual-Ready ToolsCompare Repair QuoteQuote Shield Pro

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.

Rather have a pro handle this?

A certified mobile mechanic comes to your home or office. They bring the tools, you stay comfortable. No tow truck, no waiting room, no surprises.

Comes to youSame-day available12-month warranty
Get a Free Quote

No obligation. See pricing before you book.