Windshield: Service and Repair

WINDSHIELD GLASS

Windshield Glass:

Windshield Glass:

Windshield Glass:

REMOVAL

1. REMOVE COOL AIR INTAKE DUCT SEAL
2. REMOVE ENGINE ROOM SIDE COVER LH
3. REMOVE ENGINE ROOM SIDE COVER RH
4. REMOVE FRONT UPPER FENDER PROTECTOR LH
5. REMOVE FRONT UPPER FENDER PROTECTOR RH
6. REMOVE ROOF DRIP SIDE FINISH MOULDING LH
7. REMOVE ROOF DRIP SIDE FINISH MOULDING RH
8. REMOVE NO. 1 WINDSHIELD OUTSIDE MOULDING CLIP
9. REMOVE FRONT WIPER ARM HEAD CAP
10. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH
11. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH
12. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY
13. REMOVE FRONT DOOR SCUFF PLATE LH (w/o Illumination)
14. REMOVE FRONT DOOR SCUFF PLATE LH (w/ Illumination)
15. REMOVE FRONT DOOR OPENING TRIM COVER LH
16. REMOVE FRONT PILLAR GARNISH LH
17. REMOVE FRONT DOOR SCUFF PLATE RH (w/o Illumination)
18. REMOVE FRONT DOOR SCUFF PLATE RH (w/ Illumination)
19. REMOVE FRONT DOOR OPENING TRIM COVER RH
20. REMOVE FRONT PILLAR GARNISH RH
21. REMOVE INNER REAR VIEW MIRROR STAY HOLDER COVER
22. REMOVE MAP LIGHT ASSEMBLY
23. REMOVE INNER REAR VIEW MIRROR ASSEMBLY
24. REMOVE ASSIST GRIP SUB-ASSEMBLY
25. REMOVE VISOR BRACKET COVER
26. REMOVE VISOR ASSEMBLY LH
27. REMOVE VISOR ASSEMBLY RH
28. REMOVE VISOR HOLDER
29. REMOVE RAIN SENSOR
30. REMOVE ROOF HEADLINING ASSEMBLY (w/o Sliding Roof)
It is not necessary to completely remove the roof headlining assembly. Slightly lower the front section of the roof headlining assembly so that the windshield glass can be removed.

31. REMOVE ROOF HEADLINING ASSEMBLY (w/ Sliding Roof)
It is not necessary to completely remove the roof headlining assembly. Slightly lower the front section of the roof headlining assembly so that the windshield glass can be removed.

32. REMOVE WINDSHIELD OUTSIDE MOULDING





a. Using a knife, cut off the moulding, as shown in the illustration.

NOTICE: Do not damage the vehicle body with the knife.

b. Remove the remaining moulding from the vehicle body.

HINT: When removing, make a partial cut, then pull and remove it by hand.

33. REMOVE WINDSHIELD GLASS





a. Pass a piano wire between the vehicle body and glass from the interior.
b. Tie both wire ends to wooden blocks or similar objects.

NOTICE:
- When separating the glass, take care not to damage the paint and the interior and exterior ornaments.
- To prevent the safety pad from being scratched when removing the glass, place a plastic sheet between the piano wire and safety pad.

HINT: Apply protective tape to the outer surface to prevent the surface from being scratched.





c. Place matchmarks over the glass and vehicle body on the locations indicated in the illustration.

HINT: Matchmarks do not need to be placed if the glass is not going to be reused.

d. Cut off the adhesive by pulling the piano wire around the glass.
e. Using a suction cup, remove the glass.

NOTICE: Leave as much adhesive on the vehicle body as possible when removing the glass.

34. REMOVE NO. 2 WINDSHIELD GLASS STOPPER
a. Using a scraper, remove the No. 2 windshield glass stoppers.

35. REMOVE NO. 1 WINDSHIELD GLASS STOPPER
a. Remove the No. 1 windshield glass stoppers.

36. CLEAN WINDSHIELD GLASS





a. Using a scraper, remove the damaged stoppers, dam and adhesive sticking to the glass.
b. Clean the outer circumference of the glass with non-residue type solvent.

NOTICE:
- Do not touch the glass surface after cleaning it.
- Be careful not to damage the glass.
- Even if using new glass, clean the glass with non-residue type solvent.

INSTALLATION

1. INSTALL NO. 1 WINDSHIELD GLASS STOPPER





a. Install 2 new stoppers to the vehicle body, as shown in the illustration.

2. INSTALL NO. 2 WINDSHIELD GLASS STOPPER
a. Coat the installation part of the stopper with Primer G.

NOTICE:
- Allow the primer coating to dry for 3 minutes or more.
- Do not keep any of the opened Primer G for later use.
- Do not apply too much primer.

b. Install 2 new windshield glass stoppers onto the glass, as shown in the illustration.








3. INSTALL WINDSHIELD OUTSIDE MOULDING
a. Using a brush or sponge, coat the edge of the glass and the contact surface with Primer G.

NOTICE:
- Allow the primer coating to dry for 3 minutes or more.
- Do not coat the adhesive with Primer G.
- Do not keep any of the opened Primer G for later use.








b. Install the windshield outside moulding, as shown in the illustration.

4. INSTALL WINDSHIELD GLASS ADHESIVE DAM
a. Coat the installation part of the dam with Primer G.

NOTICE:
- Allow the primer coating to dry for 3 minutes or more.
- Do not apply too much primer.

b. Install a new dam, applying double-sided tape all the way around the glass except where the dam is installed, as shown in the illustration.








5. INSTALL WINDSHIELD GLASS
a. Clean and shape the contact surface of the vehicle body.





1. Using a knife, cut away any rough adhesive on the contact surface of the vehicle body to ensure the appropriate surface shape.

NOTICE: Be careful not to damage the vehicle body.

HINT: Leave as much adhesive on the vehicle body as possible.

2. Clean the contact surface of the vehicle body with a piece of shop rag saturated with cleaner.

HINT: Even if all the adhesive has been removed, clean the vehicle body.

b. Position the glass.





1. Using a suction cup, place the glass in the correct position.
2. Check that the whole contact surface of the glass rim is perfectly even.
3. Place reference marks between the glass and vehicle body.

NOTICE: Check that the stoppers are attached to the vehicle body correctly.

HINT: When reusing the glass, check and correct the reference mark positions.

4. Remove the glass.





c. Using a brush, coat the exposed part of the vehicle body on the vehicle side with Primer M.

NOTICE:
- Allow the primer coating to dry for 3 minutes or more.
- Do not coat the adhesive with Primer M.
- Do not keep any of the opened Primer M for later use.

d. Using a brush or sponge, coat the edge of the glass and the contact surface with Primer G.








NOTICE:
- Allow the primer coating to dry for 3 minutes or more.
- Do not keep any of the opened Primer G for later use.

HINT: If an area other than that specified is coated by accident, wipe off the primer with a clean piece of cloth before it dries.

e. Apply adhesive (Adhesive: Part No. 08850-00801 or equivalent).
1. Cut off the tip of the cartridge nozzle, as shown in the illustration.

HINT: After cutting off the tip, use all adhesive within the time described in the table below.





2. Load the sealer gun with the cartridge.
3. Coat the glass with adhesive, as shown in the illustration.








f. Install the glass.





1. Using a suction cup, position the glass so that the reference marks are aligned, and press it in gently along the rim.

NOTICE:
- Allow the primer coating to dry for 3 minutes or more.
- Check that the stoppers are attached to the vehicle body correctly.
- Check the clearance between the vehicle body and glass.

2. Lightly press the front surface of the glass to ensure a close fit.





3. Using a scraper, remove any excess or protruding adhesive.

NOTICE: Do not drive the vehicle for the time described in the table below.





HINT: Apply adhesive onto the glass rim.

6. CHECK FOR LEAKS AND REPAIR
a. Conduct a leak test after the adhesive has completely hardened.
b. Seal any leaks with a sealer gun.

7. INSTALL ROOF HEADLINING ASSEMBLY (w/o Sliding Roof)
8. INSTALL ROOF HEADLINING ASSEMBLY (w/ Sliding Roof)
9. INSTALL RAIN SENSOR TAPE
10. INSTALL RAIN SENSOR
11. INSTALL VISOR HOLDER
12. INSTALL VISOR ASSEMBLY LH
13. INSTALL VISOR ASSEMBLY RH
14. INSTALL VISOR BRACKET COVER
15. INSTALL ASSIST GRIP SUB-ASSEMBLY
16. INSTALL INNER REAR VIEW MIRROR ASSEMBLY
17. INSTALL MAP LIGHT ASSEMBLY
18. INSTALL INNER REAR VIEW MIRROR STAY HOLDER COVER
19. INSTALL FRONT PILLAR GARNISH LH
20. INSTALL FRONT DOOR OPENING TRIM COVER LH
21. INSTALL FRONT DOOR SCUFF PLATE LH (w/o Illumination)
22. INSTALL FRONT DOOR SCUFF PLATE LH (w/ Illumination)
23. INSTALL FRONT PILLAR GARNISH RH
24. INSTALL FRONT DOOR OPENING TRIM COVER RH
25. INSTALL FRONT DOOR SCUFF PLATE RH (w/o Illumination)
26. INSTALL FRONT DOOR SCUFF PLATE RH (w/ Illumination)
27. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY
28. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH
29. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH
30. INSTALL FRONT WIPER ARM HEAD CAP
31. INSTALL NO. 1 WINDSHIELD OUTSIDE MOULDING CLIP
32. INSTALL ROOF DRIP SIDE FINISH MOULDING LH
33. INSTALL ROOF DRIP SIDE FINISH MOULDING RH
34. INSTALL FRONT UPPER FENDER PROTECTOR LH
35. INSTALL FRONT UPPER FENDER PROTECTOR RH
36. INSTALL ENGINE ROOM SIDE COVER RH
37. INSTALL ENGINE ROOM SIDE COVER LH
38. INSTALL COOL AIR INTAKE DUCT SEAL