Windshield: Service and Repair

Windshield Glass:

REMOVAL
1. To remove the windshield, first remove the following parts:
1. Front pillar trims
2. Inside rear view mirror
3. Wiper arms
4. Cowl top cover




5. Windshield glass molding




2. Use the Special Tool (09861 - 31100) to cut through the sealant.
3. 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.




4. Take out the windshield glass with Special Tool, Glass Holder.

INSTALLATION




1. Using a cutter knife or the Special Tool, scrape the old sealant smoothly to a thickness of about 2 mm (0.08 in.) on the bonding surface around the entire windshield flange.

CAUTION: Be careful not to remove more adhesive than necessary, and also not to damage the paintwork on the body surface with the knife. If the paintwork is damaged, repair the damaged area with touch-up paint.

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




3. Center a new windshield glass in the opening. Mark the location by scribing lines across the glass and body with a grease pencil at the four points as shown.







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




5. Install the windshield glass molding without any gaps.




6. Apply a light coat of glass primer to the outside of the dam.

NOTE:
1. Never touch the primed surfaces with your hand. If you do, the adhesive may not bond to the glass properly, causing a leak after the windshield glass is installed.
2. Do not apply body primer to the glass.
3. Keep water, dust, and abrasive materials away from the primed surface.




7. Apply a light coat of body primer to the original sealant remaining around the window opening flange. The glass should be installed 10 minutes after you apply the primer.
8. Pack adhesive into the cartridge avoiding air pockets, 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.

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

9. Using suction cups or Special Tool, lower the glass over the opening, align it with the marks made in step 3 and set it down on the sealant.




10. Scrape or wipe excess adhesive off with a putty knife or gauze. Fill all cavities around the windshield glass.
11. Perform a water-leak test for the windshield. Use a cold water spray, being careful not to direct a powerful stream of water on the new adhesive material. Allow water to spill over the edges of the glass.




12. 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).