Windshield: Service and Repair

WINDSHIELD GLASS

Windshield Glass:

COMPONENTS

REMOVAL

CAUTION
- Wear gloves to remove and install the windshield glass.
- Use seat covers to avoid damaging any surfaces.

1. To remove the windshield glass, first remove the following parts:
1. Inside rear view mirror.
2. Wiper arms
3. Cowl top cover
4. Front pillar trims
5. Sunvisors and assist handles




2. Peel off the molding and remove the windshield glass spacer.

NOTE: When molding removal is difficult, cut the molding with a knife.

3. Pull down the front of the headlining.




4. In order to protect the body (paint surface), apply cloth tape to all body flange around the installed windshield glass.
5. Using a sharp-point drill, make a hole in the windshield glass adhesive. Pass the piano wire from the inside of the vehicle through the hole. Pull the piano wire alternately from the inside and outside along the windshield glass to cut the adhesive.

CAUTION: Do not let the piano wire touch the edge of the windshield glass. Hold the piano wire as close to the windshield glass as possible to prevent damage to the body.




6. Make mating marks on the glass and body if the glass is to be reinstalled.

NOTE: Use chalk or equivalent to make mating marks on the glass and body.

7. Take out the windshield glass with the Special Tool, Glass Holder.
8. Check the body flange for deformation.

INSTALLATION




1. Using a cutter knife or the Special Tool, scrape the old sealant smoothly to a thickness of about 2 mm (0.080 in.) on the bonding surface around the entire body flange.

CAUTION: Be careful not to remove more adhesive than necessary, and also not to damage the paint work on the body surface with the knife. If the paint work is damaged, repair the damaged area with repair paint or antirust agent.

Clean the body bonding surface with a sponge dampened in alcohol or grease remover.

2. When reusing the glass, remove the adhesive still adhered to the glass, and clean with isopropyl alcohol.
Clean the body side in the same way.

CAUTION: Let the cleaned areas stand for 1 minutes or more, and carry out the next procedures after they have dried. Also, do not touch any surface that has been cleaned.




3. Install the windshield glass spacer at the locations as shown in illustration.




4. When replacing the glass, temporarily set the glass against the body, and place mating marks on the glass and body. Use unleaded petrol to degrease the inside and outside of the windshield glass and the body flanges.




5. Evenly apply a light coat of glass primer to the windshield glass and then let it dry for 1 to 15 minutes.

NOTE:
1. Do not apply body primer to the glass.
2. The primer strengthens the adhesive, so be sure to apply it evenly around the entire circumference. Also, a too thick application will weaken the adhesive.
3. Never touch the primed surface with your hand. If you do, the adhesive may not bond to the glass properly, causing a leak after the windshield is installed.
4. Keep water, dust, and abrasive materials away from primed surface.




6. Glue the rubber dam to the inside surface of the windshield glass around the edge as shown, to contain the sealant during installation.




7. Apply the light coat of body primer to the original sealant remaining around the body flange. The glass should be installed 10 minutes after you apply the primer.




8. Pack adhesive into the cartridge without air packets, to ensure continuous application. Put the cartridge in a caulking gun or Sealant Gun, and run a bead of adhesive around the edge of the glass as shown.

NOTE: Apply the adhesive within 5 minutes after applying the glass primer.




9. Using the suction cups or the Special Tool (09861-31400), lower the glass over the opening to align it with the marks made in step 4 and set it down on the sealant. Insert two lower spacers to prevent the windshield from moving downward.




10. Align marks of the windshield glass molding (white point in the glass molding) and inside roof molding.

11. Press the glass molding from center of the car to the left pillar and right pillar simultaneously.

12. Let the adhesive dry for at least one hour, then spray water over the windshield and check for leaks. If there are leaks, dry the affected area, then apply sealant.

NOTE:
- Let the car stand for at least four hours after windshield installation. If the car has to be used within the first 8 hours, it must be driven slowly.
- Keep the windshield dry for the first hour after installation.

13. Install the removed parts.

NOTE:
Advise the customer not to do the following things for two to three days:
- Slam the doors with all the windows rolled up.
- Twist the body excessively (such as when going in and out of driveways at an angle or driving over rough, uneven roads).