Windshield: Service and Repair

REMOVAL AND INSTALLATION

REMOVAL SERVICE POINT

WINDSHIELD REMOVAL
1. To protect the body (paint surface), apply cloth tape to all body areas around the installed windshield.
2. Cut the molding with a cutter knife.




3. Using a sharp-point drill, make hole in the windshield adhesive.
4. Pass the piano wire from the inside of the vehicle through the hole.
5. Pull the piano wire alternately from the inside and outside along the windshield to cut the adhesive.

CAUTION: Do not let the piano wire touch the edge of the windshield.

6. Make mating marks on the windshield and body.




7. Use the special tool to remove the windshield.




8. Use a knife to cut away the remaining adhesive so that the thickness is within 2 mm (0.08 in.) around the entire circumference of the body flange.
9. Finish the flange surfaces so that they are smooth.

CAUTION:
1. Do not remove more adhesive than is necessary.
2. Do not damage the paintwork on the body surface with the knife. If the paintwork is damaged, repair the damaged area with repair paint or anti-rust agent.
10. When reusing the windshield, remove the adhesive still adhering to the windshield, and clean with isopropyl alcohol.
11. Clean the body side in the same way.

CAUTION: Let the cleaned places stand for 3 minutes or more, and carry out the next procedures after they have dried. Also, do not touch any surface that has been cleaned.

INSTALLATION SERVICE POINTS

>A< DUAL-LOCK FASTENER INSTALLATION
1. Wipe the windshield section in the figure with isopropyl alcohol to clean it and to remove all grease, etc.
2. Attach the dual-lock fastener in the places shown in the illustration so that there are no bends or wrinkles on the windshield or the body.




>B< WINDOW SPACER INSTALLATION
Install the window spacers to the windshield in the places shown in the illustration.




>C< WINDSHIELD MOLDING INSTALLATION
Apply specified double-sided tape to the windshield in the places shown in the illustration, and then install the windshield molding.
Specified adhesive tape:
3M ATD Part No.6382 or equivalent




>D< WINDSHIELD INSTALLATION
1. Soak a sponge in the primer, and apply evenly to the glass and the body in the places shown in the illustration.
Specified primer:
3M ATD Part No.8608 Super Fast Urethane Primer or equivalent

CAUTION:
1. Apply the primer evenly around the entire circumference, because it strengthens the adhesive. Otherwise, a too thick application will cause lowering of the adhesive strength.
2. Do not touch the coated surface.
2. After applying the primer; let it dry for 3 to 30 minutes.




3. Within 30 minutes after applying the primer, use a sealant gun to apply the adhesive evenly over the adhesive surface of he vehicle body.
Specified adhesive:
3M ATO Part No.8609 Super Fast Urethane or equivalent

NOTE: Cut the nozzle tip of the sealant gun into a V shape to facilitate adhesive application.

4. After aligning the mating marks, press the glass gently and evenly so that it adheres completely.
5. After completion of this operation (after installing the glass), place it somewhere where it will not be disturbed, until the adhesive sets.

CAUTION: If heat is applied with an infra-red light to shorten the setting time, keep the surface temperature of the adhesive below 60° C (140° F)

6. After attaching the windshield to the body, let it stand for 30 minutes or more, and then test for water leakage.

CAUTION:
1. If moving the vehicle, it should be done gently.
2. When testing for water leakage, do not pinch the end of the hose to spray the water.