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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