Windshield

Complete removal and installation of the windshield glass assembly on a 2009 Aston Martin DB9, including cowl trim, wiper assembly, and urethane adhesive bond procedures.

Warnings

Tools required

Parts

• Windshield glass assembly × 1 — OEM Aston Martin DB9 windshield with heated element and antenna
• Windshield urethane adhesive × 1 — Use OEM-approved automotive grade urethane
• Urethane primer × 1 — Use system-matched primer for glass and body
• Cowl panel weather seal × 1 — Inspect and replace if damaged
• Windshield trim molding clips × 1 — As needed for damaged clips

Fluids

• washer — 4.2 qt

Preparation

1. Park vehicle on level surface in a clean, dry workspace with adequate lighting and ventilation.
2. Disconnect negative battery terminal and wait 10 minutes for airbag system capacitors to discharge.
3. Cover dashboard, instrument cluster, and both A-pillar trim areas with protective blankets.
4. Remove rearview mirror by rotating base counterclockwise and disconnecting any electrical connectors for auto-dimming or camera features.
5. Drain windshield washer fluid reservoir if access is required from engine compartment.

Procedure

1. 1

   Remove wiper arms
   Lift each wiper arm away from windshield. Remove the plastic cap covering the wiper arm nut at the base of each arm. Using appropriate socket, remove the retaining nut from each wiper arm spindle. Mark wiper arm position on windshield with tape for reinstallation reference. Pull wiper arms straight off the splined spindles using rocking motion. Remove both driver and passenger wiper arms.
2. 2

   Remove cowl panel and trim
   Open the hood. Remove the rubber weather seal running along the rear edge of the hood opening at the cowl. Locate and remove the fasteners securing the plastic cowl cover panel (verify exact fastener type and size against factory documentation for this vehicle). The panel is secured at multiple points along its length. Carefully lift the cowl panel upward and rearward to disengage any retaining clips. Disconnect the washer fluid hoses from the washer nozzles if they pass through the cowl panel. Remove the cowl panel and set aside. Note: Press down to engage any retaining clips, then install all cowl panel fasteners (verify exact fastener type, size, and count against factory documentation for this vehicle).
3. 3

   Disconnect windshield electrical connections
   If the vehicle is equipped with a heated windshield, locate the electrical connectors for the heated elements (typically behind A-pillar trim or accessible from the cowl area) and disconnect them. If equipped with an in-glass antenna amplifier, locate and disconnect its connector. Label all connectors for reinstallation. Verify actual equipment for this specific VIN before disconnecting. Note: If equipped with a heated windshield, locate the electrical connectors for the heated windshield elements at the lower corners of the windshield (typically behind A-pillar trim or accessible from cowl area). Disconnect both left and right heated element connectors if present.
4. 4

   Remove A-pillar interior trim
   From inside the vehicle, carefully pull the upper A-pillar trim covers away from the windshield frame on both sides. These are typically held by plastic clips. Work from top to bottom, releasing clips carefully with plastic trim tools. Remove or fold back any headliner edge trim that overlaps the windshield opening. This provides access to the windshield urethane bond area and prevents interior damage during glass removal.
5. 5

   Remove exterior windshield molding
   Inspect the windshield perimeter for exterior chrome or black molding trim. On the DB9, molding may be clipped or adhered to the windshield or body. Carefully pry out molding starting from one corner using plastic trim tools. Work around the entire perimeter removing all molding sections. Inspect and retain any reusable clips. Note the molding installation sequence for reinstallation.
6. 6

   Cut urethane bond from inside vehicle
   From inside the vehicle, using a cold knife or urethane removal tool, carefully cut through the urethane adhesive bond between the windshield and body frame. Start at a lower corner and work methodically around the entire perimeter. Keep the blade angle shallow (nearly parallel to the glass) to avoid scratching the body pinch weld or damaging the glass edge. Cut fully through the urethane adhesive around the perimeter, working methodically. Have an assistant support the glass from outside as you near completion of the cut. Have an assistant support the glass from outside as you near completion of the cut.
7. 7

   Remove windshield glass
   With two people and suction cup handlers positioned outside the vehicle, complete the final urethane cuts at the top corners. Both installers should use suction cup handles attached to the windshield glass. Apply steady outward pressure while lifting upward to break the remaining urethane bond. Once free, carefully lift the windshield up and away from the vehicle. Carry the glass to a safe padded area and set vertically with proper support. Inspect the glass for any damage if it is being reused.
8. 8

   Clean windshield frame opening
   Using a razor blade scraper and cold knife, remove all old urethane from the body pinch weld. Leave a thin uniform layer (approximately 1-2mm) of the old urethane as a base if it is well-bonded; otherwise, remove down to bare metal. Inspect the pinch weld for rust, damage, or distortion. Clean the entire perimeter thoroughly with isopropyl alcohol and allow to dry completely. Inspect and clean any corrosion from the pinch weld, applying touch-up primer if bare metal is exposed.
9. 9

   Prepare new windshield glass
   If installing a new windshield, ensure it is the correct part with heated elements and antenna if originally equipped. Clean the ceramic frit band (black edge) around the entire perimeter of the windshield with isopropyl alcohol. Allow to dry completely. Apply urethane glass primer to the ceramic frit band according to primer manufacturer instructions. Apply primer in a smooth continuous bead around the entire perimeter of the glass on the bonding surface. Allow primer to flash off per manufacturer specifications (typically 5-10 minutes).
10. 10

    Apply body primer and urethane adhesive
    Apply urethane body primer to the cleaned pinch weld surface according to manufacturer instructions. Allow proper flash time. Load automotive windshield urethane adhesive into the application gun. Apply a continuous bead of urethane to either the body pinch weld or the primed windshield glass edge (follow adhesive system instructions for application location). The bead should be uniform, approximately 10-12mm wide and 10-12mm tall, with no gaps or thin spots. Apply the bead smoothly around the entire windshield perimeter.
11. 11

    Install windshield glass
    With two installers using suction cup handlers, carefully position the windshield above the opening. Align the glass to the body opening using the visible edges and pillar positions as reference. Use tape markers if placed during removal for alignment reference. Lower the windshield into position, seating it evenly into the urethane adhesive. Apply firm even pressure around the entire perimeter to ensure proper adhesive contact and compress the urethane to proper thickness. Check gap uniformity around the entire perimeter from inside and outside the vehicle.
12. 12

    Secure and cure windshield
    Use tape strips from the windshield glass to the body panels at multiple locations around the perimeter to hold the glass in position during cure. Do not apply excessive tension. Inspect the urethane bead from inside the vehicle; it should show a uniform compressed bead with no gaps. Allow the urethane to cure according to manufacturer specifications before proceeding with further assembly or moving the vehicle. Minimum drive-away time is typically 1 hour for safe handling, with full cure in 24 hours.
13. 13

    Reconnect electrical connections
    Once urethane has reached safe-handling cure time, reconnect the heated windshield element connectors at both lower corners of the windshield. Ensure connections are fully seated and locked. Reconnect the windshield antenna amplifier connector if equipped. Verify proper connection of all electrical components.
14. 14

    Reinstall exterior molding and interior trim
    Reinstall the exterior windshield molding in reverse order of removal. Ensure all clips are properly seated and the molding is uniform around the perimeter. From inside the vehicle, reinstall the A-pillar trim covers by aligning and pressing firmly to engage all retaining clips. Reinstall any headliner edge trim that was removed. Ensure all interior trim pieces are fully seated and secure.
15. 15

    Reinstall cowl panel and wiper assembly
    Reconnect washer fluid hoses to the washer nozzles. Position the cowl panel and align with body mounting points. Press down to engage any retaining clips, then install all Torx fasteners securing the cowl panel. Reinstall the rubber weather seal along the cowl edge. Position each wiper arm on its spindle according to the reference marks made during removal. Install the retaining nuts and torque to the Aston Martin factory specification for the DB9 wiper arm spindle nuts (verify exact torque in the workshop manual before final tightening). Install the plastic caps over the wiper arm nuts. Reconnect the negative battery terminal. Note: Install the retaining nuts and torque to the Aston Martin specified value (verify exact torque spec for this vehicle before final tightening). Note: Install the retaining nuts and torque to the Aston Martin DB9 factory specification (verify exact torque in the workshop manual before tightening).

Reassembly

1. Reinstall rearview mirror by connecting electrical connectors and rotating base clockwise until locked.
2. Refill windshield washer fluid reservoir to proper level with windshield washer fluid (4.2 quarts capacity).
3. Test wiper operation at all speeds and washer spray pattern after adhesive has cured sufficiently.
4. Test heated windshield operation and verify proper antenna reception if equipped.
5. If vehicle is equipped with rain sensor or forward-facing camera in windshield area, recalibration may be required using Aston Martin diagnostic equipment.

Verification

• Visually inspect windshield installation from inside and outside vehicle for uniform gaps and proper seating around entire perimeter.
• Check for any air or water leaks by inspecting urethane seal from inside vehicle; there should be no gaps or voids visible.
• Verify all electrical connections for heated windshield and antenna are functioning properly.
• Confirm wiper arms are properly positioned and clear the windshield through full sweep without interference.
• Test vehicle at low speeds after minimum cure time and listen for any wind noise or water leaks around windshield perimeter.
• After full 24-hour cure, perform road test at highway speeds to confirm proper installation with no leaks or wind noise.

More procedures for this vehicle