2009 Honda Pilot

Sponsored by Dow Automotive

Vehicle type: Four-door sport-utility vehicle

NAGS numbers*: Windshield part numbers FW2925 solar, FW2926 solar, acoustic interlayer, electrochromatic mirror; front door glass R/L FD23786/87 solar; rear door glass R/L FD23788/89 solar; vent glass FV23790/91 solar; quarter glass FQ23792/93 solar, antenna; and back glass FB23794 solar, heated

Helpful tools or supplies: Cutout wire for the quarter glass and an extra back glass handle and latch. The latter may be missing if the glass was broken. Have an additional technician on hand to help install the back glass.

Watch for: The quarter glass is in close proximity to the wall of the pinchweld and does not have molding around the perimeter. Cutting this part from the vehicle without any damage will be a challenge if you want to salvage the glass.

*With permission from National Auto Glass Specifications. Call NAGS at 800/551-4012 or visit http://glass.mitchell.com/.

A. Windshield
Preparation
1. Cover the front seats, floorboards, dash and steering wheel with a clean drop cloth or disposable plastic covers. Note: Always wear eye and hand protection when working with glass. Make sure you have the right glass and moldings, and the urethane systems you are about to use are current. Windshield part numbers are FW2925 and FW2926.

2. Drape the fender with a fender cover and tape up any vulnerable areas on the vehicle to protect against possible damage. Tape up the defroster vents to prevent debris from falling into the openings.

3. To remove the rearview mirror, loosen the set Phillips screw at the base of the mirror and slide the mirror off the pad. Note, there is a wire cover.

4. Remove the windshield-wiper nuts using a 15-millimeter wrench or socket. Move the wiper arm in an up-and-down motion to break it loose from the post, or use a wiper-puller. Caution: Wipers can sometimes be hard to remove. To avoid stressing the post, use a wiper-puller. 

5. The top molding is a wraparound molding that you will need to pull out to facilitate cutout. 

6. The side moldings are clipped down. To release, force the tip of a stiff plastic tool or taped-up molding release tool between the molding and the A pillar. Pry upward, back to front, to release the clips. Damage to the clips is less likely to occur using this method; however, have a clip kit available before beginning windshield removal and replacement.

7. Remove the push-in retainers along the leading edge of the cowl using your fingers or a door-pad tool. Lift the cowl panel and slide it out from under the windshield lower edge. Put the panel in a safe place. Note: Before beginning windshield removal, verify the new windshield is the correct one and the urethanes and primers are current. Never use outdated products as this could jeopardize the structural integrity of the vehicle and the safety of its passengers.

Removal
8. Make sure cutting blades are sufficiently sharp.

9. Before cutting out the windshield, remove contaminants from the glass and pinchweld to prevent contact with the urethane.

10. Use the cutting tool of your choice to remove the glass from the adhesive bead. Note: When using any power tool, lubricate the cutting area with water. Spray the top and sides; then make your cuts. Be careful not to hit or cut the gravity stops; mark their location with a marking pencil or molding-retention tape.

11. After cutting the sides and top, cut out the bottom portion of the glass. Spray the bottom of the windshield with water at least 4-to-5 inches above the urethane on the glass, so the water flows down into the urethane while you make your final cut across the bottom of the windshield. Caution: Never use your head to push, as this could result in back and neck injuries.

12. Take the windshield out of the opening using a set of vacuum cups. Make sure the vacuum cups do not overlap a crack in the glass. Lift the glass and place it on a windshield stand or suitable workstation.

Installation
13. After cutting the windshield out, remove contaminants such as dirt, moisture and debris from the pinchweld. Clean the dashboard.

14. Attach the top molding to the edge of the glass.

15. Dry fit the new glass to the opening. Mark your glass using a grease pencil or molding-retention tape.

16. Place your vacuum cups on the windshield in the appropriate location.

17. Set the windshield onto the old urethane.

18. With the windshield resting in the opening, make sure it is in the right spot.

19. Adjust both sides to the correct setting, marking the passenger’s side, then the driver’s side. Lift the glass and place it on a windshield stand or suitable workstation.

20. Follow the urethane manufacturer’s recommendations for installation.

21. Clean the inside of the windshield using a urethane manufacturer-recommended product. Do not touch the bonding area of the windshield after cleaning, prepping or priming it.

22. Wear powder-free Nitrile gloves to keep off chemicals.

23. Apply the glass prep and primer following the urethane manufacturer’s recommendations.

24. Using the tool of your choice, remove the original urethane bead, leaving 1-2 millimeters of existing urethane on the pinchweld. Make sure there are no contaminants and do not touch the pinchweld after prepping the area.

25. Apply the pinchweld primer only to the areas where needed and follow the urethane manufacturer’s recommendations. Allow preps and primers to dry as recommended by the urethane manufacturer.

26. Apply a triangular bead of urethane to the same path as the freshly cut urethane on the pinchweld. Before cutting your V-notch, cut the tip off of your nozzle with a nozzle-cutter. With the cut nozzle, measure to the top of the roofline, and at 1/16-inch higher than the roofline, make a mark on the nozzle with a pen or marker. Notch the nozzle up to the marked line; this will give you the appropriate triangular bead.

27. Lift the windshield from the windshield stand or workstation using vacuum cups. Set the windshield on the urethane at the mark you made during your dry fit. Lower the driver’s side of the windshield onto the urethane and line it up with the dry-fit mark; it is now in place.

28. Press firmly to ensure a good seal.

29. Before re-installing the parts, check for leaks. Use a leak detector to go over the perimeter of the windshield. If you find a leak, apply pressure or add more urethane to the spot and ensure that the glass makes contact with the wet urethane.

30. Re-install the removed parts in reverse order.

31. Allow the urethane to cure according to the urethane manufacturer’s recommended cure time before returning the vehicle to the customer. Warning: Disregarding the safe drive-away time that your urethane manufacturer recommends could jeopardize the structural integrity of the vehicle and the safety of its passengers.

32. You have completed the removal and replacement of the windshield.

B. Front door glass
Removal
1. Make sure you have the right glass. Front door glass part numbers are FD23786/87.

2. Using a pick or pocket screwdriver, remove the screw cover from behind the door handle.

3. Remove the two Phillips screws.

4. Remove the additional Phillips screw from under the door pull.

5. Remove the outside rearview mirror mounting cover from the interior front portion of the door.

6. Pry out the window instrument cluster from the armrest. It is held in place with three easily released clips. Start in the front and lift to gain access to the wire connectors.

7. Disconnect the wiring harness from the window instrument cluster and set aside. To release the connector, lift up and pivot the white retainer clip.

8. Pry the door panel from the door frame. Release the retainers using a door-pad tool or your hands to grasp and pull. Once you’ve released all of the perimeter clips, lift the panel off the door frame.

9. Disconnect the door latch and lock linkage. Turn the lower entrance light bulb socket 1/4 turn to the right and release from the panel.

10. Remove the door panel and set it in a safe place.

11. Remove the top beltline weatherstrip for easy insertion of the door glass.

12. Lower the regulator to access the 10-millimeter mounting bolts. Note, the new glass will come bonded with the tabs on the lower edge of the glass.

13. Remove the 10-millimeter bolts and lift the glass out of the door.

Installation
14. Clean out all of the glass from the door frame and window frame weatherstripping.

15. Insert the glass into the door frame and make sure the glass travels smoothly up and down in the vertical run guide. Line up the tabs to the regulator mounting panel.

16. Insert the 10-millimeter bolts and secure the glass assembly to the mounting panel.

17. This vehicle is equipped with the power-up feature and requires the resetting of the anti-pinch feature. Follow steps 18-24 to reset.

18. Push and hold the window switch to lower the glass to the full down position.

19. Hold the window switch for at least five seconds.

20. Pull and hold the window switch to raise the window to the full up position.

21. Hold the switch for at least five seconds.

22. Test window operation in automatic mode. The glass should raise and lower properly with the automatic switch depressed and released. If it does not, repeat the process until the window performs properly.

23. Check to ensure the window’s automatic reverse function performs properly. Take a rubber mallet or shim and place it between the top of the glass and the top of the window frame. Activate the automatic power-up window switch, but do not hold the window switch. The glass should contact the rubber shim and reverse its travel. If not, reset.

24. If after resetting six to 10 times without success, disconnect the power to the regulator motor, wait for one minute, reconnect and try resetting again. If it still does not operate properly, take the vehicle to a dealer for recalibration.

25. Re-install the remaining parts in reverse order of removal and check window operation again.

26. You have completed the removal and replacement of the front door glass.

C. Rear door glass
Removal
1. Make sure you have the right glass. Rear door glass part numbers are FD23788/89.

2. Using a pick or pocket screwdriver, remove the screw cover from behind the door handle.

3. Remove the two Phillips screws.

4. Remove the additional Phillips screw from under the door pull.

5. Pry the door panel from the door frame. Release the retainers using a door-pad tool or your hands to grasp and pull. Once you’ve released all of the perimeter clips, lift the panel off the door frame.

6. Disconnect the wiring harness from the window instrument cluster and set aside.

7. Disconnect the door latch and lock linkage. Turn the lower entrance light bulb socket 1/4 turn to the right and release from the panel.

8. Remove the door panel and set it in a safe place.

9. Remove the top beltline weatherstrip for easy insertion of the door glass. Note, it may also be necessary to displace the front and rear vertical weatherstrip from its housing to facilitate glass insertion.

10. Lower the regulator to access the 10-millimeter mounting bolts. Note, the new glass will come bonded with the tabs on the lower edge of the glass.

11. Remove the 10-millimeter bolts and lift the glass out of the door.

Installation
12. To replace the rear door glass, slip it back into door in the same manner you removed it.

13. Check operation of the glass before replacing the door panel to ensure proper installation.

14. Re-install the removed parts in reverse order.

15. You have completed the removal and replacement of the rear door glass.

D. Vent glass
Removal
1. Make sure you have the right glass. Vent glass part numbers are FV23790/91.

2. Lower the rear door glass to the full down position.

3. Using a pick or pocket screwdriver, remove the screw cover from behind the door handle.

4. Remove the two Phillips screws.

5. Remove the additional Phillips screw from under the door pull.

6. Pry the door panel from the door frame. Release the retainers using a door-pad tool or your hands to grasp and pull. Once you’ve released all of the perimeter clips, lift the panel off the door frame.

7. Pivot the door panel to access the two 10-millimeter bolts that secure the bottom and middle of the division bar. Loosen the bottom bolt and remove the middle bolt.

8. Remove the small Phillips screw located at the top of the division bar, behind the assembly weatherstrip.

9. Tilt the division bar forward to facilitate glass and gasket removal. Remove the glass and weatherstrip.

Installation
10. Clean up any broken glass, including any in the surrounding glass gasket.

11. Fit the existing gasket to the glass edge.

12. Lubricate the gasket with your preferred lubricant. The assembly is housed in a frame and bonding is not a concern.

13. Slide the glass assembly into the door frame.

14. Position the division bar to the leading edge of the glass assembly and secure with the screws and bolts removed earlier.

15. Check operation of the rear door glass.

16. Replace any remaining parts in reverse order of removal.

17. You have completed the removal and replacement of the vent glass.

E. Quarter glass
Removal
1. Make sure you have the right glass. Quarter glass part numbers are FQ23792/93. Note, the passenger side window is equipped with a built-in antenna. Take care to avoid damaging the antenna system if your goal is to salvage the glass.

2. The glass is in close proximity to the wall of the pinchweld and does not have molding around the perimeter.

Cutting this part from the vehicle without any damage will be a challenge if you want to salvage the part. However, it may not be necessary to remove the entire interior garnish moldings. On the passenger side of the vehicle’s quarter panel is an access panel that can be removed to disconnect the antenna. Once the antenna is disconnected, the glass can be cut out without interior damage to the moldings, especially if it is already fractured. If a blind cutout is required, however, remove all interior moldings.

3. To remove the interior moldings, begin with the seat belt assembly.

4. Remove the seat belt adjustment cover. Remove the seat belt bolt.

5. Remove the bolt cover marked “SRS” from the D pillar. Remove the 10-millimeter screw.

6. Remove the access panel from the C pillar. Remove the 10-millimeter bolt and disconnect the antenna lead.

7. Remove the quarter panel from the vehicle body and set aside.

8. Cut out the glass using the tool of your choice. You might need to use cutout wire to avoid damaging the vehicle body. Note: When using any power tool, lubricate the cutting area with water. Spray the top and sides; then make your cuts.

Installation
9. After cutting the quarter glass out, remove contaminants such as dirt, moisture and other debris from the pinchweld.

10. Dry fit the new quarter glass to the opening.

11. Place your vacuum cups on the glass in the appropriate location.

12. Set the glass onto the old urethane.

13. With the glass resting in the opening, make sure it is in the right spot.

14. Adjust to the correct setting. Lift the glass and place it on a windshield stand or suitable workstation.

15. Follow the urethane manufacturer’s recommendations for installation.

16. Clean the inside of the quarter glass, using a urethane manufacturer-recommended product. Do not touch the bonding area of the quarter glass after cleaning, prepping or priming it.

17. Wear powder-free Nitrile gloves to keep off chemicals.

18. Apply the glass prep and primer following the urethane manufacturer’s recommendations.

19. Using a pinchweld scraper, remove as much of the original urethane as the urethane manufacturer recommends. Before removing the old urethane, make sure there are no contaminants and do not touch the pinchweld after you prepping the area.

20. Apply the pinchweld primer only to the areas where needed and follow the urethane manufacturer’s recommendations. Allow preps and primers to dry as recommended by the urethane manufacturer.

21. Apply a triangular bead of urethane to the same path as the freshly cut urethane on the pinchweld. Before cutting your V-notch, cut the tip off of your nozzle with a nozzle-cutter. With the cut nozzle, measure to the top of the roofline, and at 1/16-inch higher than the roofline and bodyline, make a mark on the nozzle with a pen or marker. Notch the nozzle up to the marked line; this will give you the appropriate triangular bead.

22. Place your vacuum cups on the quarter glass in the appropriate location.

23. Lift the quarter glass from the windshield stand or workstation using your vacuum cups.

24. Set the quarter glass in the opening.

25. The quarter glass is now ready to be decked. Press firmly to ensure a good seal.

26. Before re-installing the parts, check for leaks. Use a leak detector to go over the perimeter of the quarter glass. If you find a leak, apply more pressure or add more urethane to the spot and ensure that the glass makes contact with the wet urethane.

27. Re-install the removed parts in reverse manner.

28. Connect the antenna and check operation.

29. Allow the urethane to cure according to the urethane manufacturer’s recommended cure time before returning the vehicle to the customer.

30. You have completed the removal and replacement of the quarter glass.

F. Back glass
Removal
1. Make sure you have the right glass. Back glass part number is FB23794. The back glass opens separately from the back deck and will come bonded with brackets for the window pistons and the upper hinges.

2. Remove the piston rod clips using a pick or slot pocket screwdriver. Remove the piston from the bracket ball.

3. Remove the wire connector covers by unsnapping them from the connector base. There are two slots in the wire covers that release the cover from its base when depressed.

4. Remove the 27T Torx screws from the window handle/latch assembly. Remove the assembly.

5. Loosen the 27T Torx bolts from the hinges and slide the glass assembly off the hinge bracket.

6. Remove the glass from the opening.

Installation
7. Attach the window handle/latch assembly to the glass.

8. Get help from another technician to position the glass in the opening until you can install the hinge bolts.

9. Once the hinges are attached to the body, re-install the pistons, reconnect the defroster and re-install any remaining parts in reverse order of removal.

10. Check operation of the back glass electrical systems.

11. You have completed the removal and replacement of the back glass.