Windshield: Service and Repair
Windshield Glass:
REPLACEMENT
HINT:
- The installation procedures are the removal procedures in reverse order. However, only installation procedures requiring additional information are included.
- A bolt without a torque specification is shown in the standard bolt chart.
1. REMOVE INNER REAR VIEW MIRROR ASSEMBLY
2. REMOVE ROOF HEADLINING ASSEMBLY
a. Remove the front door scuff plate LH and RH.
b. Remove the cowl side trim LH and RH.
c. Remove the front door opening trim weatherstrip LH and RH.
d. Remove the front pillar garnish LH and RH.
e. Remove the assist grip covers and assist grips.
f. Remove the visor LH and RH.
g. Remove the visor holder LH and RH.
h. Remove the map lamp.
i. Partially remove the roof headlining.
HINT: It is not necessary to completely remove the roof headlining. Slightly lower the front section of the roof headlining so that the windshield glass can be removed later in step 5.
3. REMOVE COWL TOP VENTILATOR LOUVER
a. Remove the 2 wiper head caps.
b. Remove the front wiper arm LH and RH.
c. Remove the hood to cowl top seal.
d. Remove the cowl top ventilator louver LH and RH.
4. REMOVE WINDSHIELD MOULDING OUTSIDE
a. Using a knife, cut off the windshield moulding outside.
NOTE: Be careful not to damage the vehicle body with the knife.
b. Remove the remaining moulding.
HINT: Make a partial cut in the moulding. Then pull and remove it by hand.
5. REMOVE WINDSHIELD GLASS
a. To prevent scratches, apply protective tape to the outer surface of the vehicle body and place a plastic sheet between the piano wire and instrument panel.
b. From the interior, insert piano wires between the vehicle body and windshield glass as shown in the illustration.
c. Tie objects that can serve as handles (for example, wooden blocks) to all wire ends.
NOTE: When separating the windshield glass from the vehicle, be careful not to damage the vehicle's paint or interior/exterior ornaments.
d. Place matchmarks over the windshield glass and vehicle body on the locations indicated in the illustration.
HINT: Matchmarks do not need to be placed if the windshield glass is not going to be reused.
e. Cut through the adhesive by pulling the piano wire around the windshield glass.
f. Disengage the stoppers.
g. Using a suction cup, remove the windshield glass.
NOTE: Leave as much adhesive on the vehicle body as possible when removing the windshield glass.
6. CLEAN WINDSHIELD GLASS
a. Using a scraper, remove the damaged stoppers, dams and adhesive from the windshield glass.
b. Clean the outer edges of the windshield glass with white gasoline.
NOTE:
- Do not touch the windshield glass surface after cleaning it.
- Even if using new windshield glass, clean the windshield glass with white gasoline.
7. CLEAN VEHICLE BODY
a. Clean and shape the contact surface of the vehicle body.
1. On the contact surface of the vehicle body, use a knife to cut away excess adhesive as shown in the illustration.
HINT: Leave as much adhesive on the vehicle body as possible.
NOTE: Be careful not to damage the vehicle body.
2. Clean the contact surface of the vehicle body with cleaner.
HINT: Even if all the adhesive has been removed, clean the vehicle body.
8. INSTALL WINDSHIELD GLASS STOPPER NO. 2
a. Apply Primer G to the installation part of the stoppers.
HINT: If primer G is applied to an area other than that which is specified, wipe off the primer with white gasoline before it dries.
NOTE:
- Allow the Primer G to dry for 3 minutes or more.
- Throw away any leftover Primer G.
- Do not apply too much Primer G.
b. Install 2 new stoppers onto the windshield glass as shown in the illustration.
9. INSTALL WINDSHIELD GLASS STOPPER NO. 1
a. Install 2 new stoppers to the vehicle body as shown in the illustration.
10. INSTALL WINDSHIELD GLASS ADHESIVE DAM
a. Apply Primer G to the windshield glass where the adhesive dam will be installed.
HINT: If primer G is applied to an area other than that which is specified, wipe off the primer with white gasoline before it dries.
NOTE:
- Allow the Primer G to dry for 3 minutes or more.
- Throw away any leftover Primer G.
- Do not apply too much Primer G.
b. Remove the peeling paper from the adhesive part of the dam. Install the dam (adhesive side) to the windshield glass (Primer G area), but exclude the stopper areas C and D as shown in the illustration.
11. INSTALL WINDSHIELD GLASS
a. Position the windshield glass.
1. Using a suction cup, place the windshield glass in the correct position.
2. Check that the entire contact surface of the windshield glass rim is perfectly even.
3. Place matchmarks over the windshield glass and vehicle body on the locations indicated in the illustration.
HINT:
- Placing matchmarks is only necessary if the windshield glass being installed is new.
If it is reused windshield glass, matchmarks should already be present.
- When reusing the windshield glass, check and correct the matchmarks position.
NOTE: Check that the stoppers are attached to the vehicle body correctly.
4. Using a suction cup, remove the windshield glass.
b. Using a brush, apply Primer M to the exposed part of the vehicle body.
NOTE:
- Allow the Primer M to dry for 3 minutes or more.
- Do not apply Primer M to the adhesive.
- Throw away any leftover Primer M.
- Do not apply too much Primer M.
c. Using a brush or sponge, apply Primer G to the contact surface of the windshield glass.
HINT: If Primer G is applied to an area other than that which is specified, wipe off the primer with white gasoline before it dries.
NOTE:
- Allow the Primer G to dry for 3 minutes or more.
- Throw away any leftover Primer G.
- Do not apply too much Primer G.
d. Apply adhesive to the windshield glass.
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 written in the table.
2. Load the sealer gun with the cartridge.
3. Apply adhesive to the windshield glass as shown in the illustration.
e. Install the windshield glass to the vehicle body.
1. Using a suction cup, position the windshield glass so that the matchmarks are aligned. Press it in gently along the rim.
2. Lightly press the front surface of the windshield glass to ensure that the windshield glass is securely fit to the vehicle body.
NOTE:
- Check that the stoppers are attached to the vehicle body correctly.
- Check that the vehicle body and windshield glass have a small gap between them.
3. Hold the windshield glass in place securely with protective tape or equivalent until the adhesive hardens.
12. INSTALL WINDSHIELD MOULDING OUTSIDE
a. Using a brush or sponge, apply Primer G to the contact surface of the windshield glass.
HINT: If primer G is applied to an area other than that which is specified, wipe off the primer with white gasoline before it dries.
NOTE:
- Allow the Primer G to dry for 3 minutes or more.
- Throw away any leftover Primer G.
- Do not apply too much Primer G.
b. Install new windshield moulding outer upper before the adhesive dries.
NOTE: Do not drive the vehicle for the amount of time written in the table.
13. CHECK FOR LEAKS AND REPAIR
a. Conduct a leak test after the adhesive has completely hardened.
b. Seal any leaks with auto sealer.