Windshield: Service and Repair
WINDSHIELD GLASSREMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
2. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP LH
3. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP RH
4. REMOVE FRONT PILLAR GARNISH LH
5. REMOVE FRONT PILLAR GARNISH RH
6. REMOVE VISOR ASSEMBLY LH
7. REMOVE VISOR ASSEMBLY RH
8. REMOVE ASSIST GRIP SUB-ASSEMBLY
9. REMOVE VISOR HOLDER LH
10. REMOVE VISOR HOLDER RH
11. REMOVE ROOM NO. 1 LIGHT ASSEMBLY
12. REMOVE ROOF HEADLINING ASSEMBLY
a. Slightly lower the front section of the roof headlining.
HINT: It is not necessary to completely remove the roof headlining.
13. REMOVE INNER REAR VIEW MIRROR ASSEMBLY
14. REMOVE FRONT WIPER ARM HEAD CAP
15. REMOVE FRONT WIPER ARM LH
16. REMOVE FRONT WIPER ARM RH
17. REMOVE COWL TOP VENTILATOR LOUVER RH
18. REMOVE COWL TOP VENTILATOR LOUVER LH
19. REMOVE HOOD TO COWL TOP SEAL
20. 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.
21. REMOVE WINDSHIELD GLASS
a. Apply protective tape to the outer surface of the vehicle body to prevent scratches.
b. From the interior, insert a piano wire between the vehicle body and glass as shown in the illustration.
c. Tie objects that can serve as handles (for example, wooden blocks) to both wire ends.
NOTE:
- When separating the glass from the vehicle, be careful not to damage the vehicle's paint or interior/exterior ornaments.
- To prevent the instrument panel from being scratched when removing the glass, place a plastic sheet between the piano wire and instrument panel.
d. Place matchmarks over the glass and vehicle body on the locations indicated in the illustration.
HINT: Matchmarks do not need to be placed if not reusing the glass.
e. Cut through the adhesive by pulling the piano wire around the glass.
NOTE: Leave as much adhesive on the vehicle body as possible when cutting through the adhesive.
f. Disengage the stoppers.
g. Using suction cups, remove the glass.
INSTALLATION
HINT: A bolt without a torque specification is shown in the standard bolt chart.
1. CLEAN WINDSHIELD GLASS
a. Using a scraper, remove the damaged stoppers, dams and adhesive sticking to the glass.
b. Clean the outer edges of the glass with white gasoline.
NOTE: Do not touch the glass surface after cleaning it. Even if using new glass, clean it with white gasoline.
2. 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.
b. Clean the contact surface of the vehicle body with cleaner.
HINT: Even if all the adhesive has been removed, clean the vehicle body.
3. INSTALL NO. 2 WINDSHIELD GLASS STOPPER
a. Apply Primer G to the installation part of the stoppers.
HINT: If primer is applied to an area that is not is specified, wipe off the primer with white gasoline before it dries.
NOTE:
- Allow the primer to dry for 3 minutes or more.
- Throw away any leftover primer.
- Do not apply too much primer.
b. Install 2 new stoppers onto the windshield glass as shown in the illustration.
4. INSTALL NO. 1 WINDSHIELD GLASS STOPPER
a. Install 2 new stoppers to the vehicle body as shown in the illustration.
5. INSTALL WINDSHIELD GLASS ADHESIVE DAM
a. Apply Primer G to the glass where the glass adhesive dams will be installed.
HINT: If primer is applied to an area that is not specified, wipe off the primer with white gasoline before it dries.
NOTE:
- Allow the primer to dry for 3 minutes or more.
- Throw away any leftover primer.
- Do not apply too much primer.
b. Remove the peeling paper from the adhesive part of the dam. Install the dam (adhesive side) to the window glass (Primer G area), but exclude the stopper areas.
6. INSTALL WINDSHIELD MOULDING OUTSIDE
a. Using a brush or sponge, apply Primer G to the contact surface of the windshield glass.
HINT: If primer is applied to an area that is not specified, wipe off the primer with white gasoline before it dries.
NOTE:
- Allow the primer to dry for 3 minutes or more.
- Throw away any leftover primer.
- Do not apply too much primer.
b. Install a new windshield moulding.
7. INSTALL WINDSHIELD GLASS
a. Position the glass.
1. Using suction cups, place the glass in the correct position.
2. Check that the entire contact surface of the glass rim is perfectly even.
3. Place matchmarks on the glass and vehicle body on the locations indicated in the illustration.
HINT:
- Placing matchmarks is only necessary when installing new glass. If it is the reused glass, matchmarks should already be present.
- When reusing the glass, check and correct the matchmark positions.
NOTE: Check that the stoppers are attached to the vehicle body correctly.
4. Using suction cups, remove the glass.
b. Using a brush, apply Primer M to the exposed part of the vehicle body.
NOTE:
- Allow the primer to dry for 3 minutes or more.
- Do not apply primer to the adhesive.
- Throw away any leftover primer.
- Do not apply too much primer.
c. Using a brush or sponge, apply Primer G to the contact surface of the glass.
HINT: If the primer is applied to an area that is not specified, apply white gasoline to a clean cloth and wipe off the excess primer.
NOTE:
- Allow the primer to dry for 3 minutes or more.
- Throw away any leftover primer.
- Do not apply too much primer.
d. Apply adhesive to the 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 glass as shown in the illustration.
e. Install the glass to the vehicle body.
1. Using suction cups, position the glass so that the matchmarks are aligned. Press it in gently along the rim.
NOTE:
- Allow the primer 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 outer surface of the glass to ensure that it is securely fit to the vehicle body.
3. Using a scraper, remove any excess or protruding adhesive.
HINT: Apply adhesive onto the glass rim.
NOTE: Do not drive the vehicle within the time written in the table.
8. INSTALL COWL TOP VENTILATOR LOUVER LH
9. INSTALL COWL TOP VENTILATOR LOUVER RH
10. INSTALL HOOD TO COWL TOP SEAL
11. INSTALL FRONT WIPER ARM LH
12. INSTALL FRONT WIPER ARM RH
13. INSTALL FRONT WIPER ARM HEAD CAP
14. INSTALL ROOF HEADLINING ASSEMBLY
15. INSTALL VISOR HOLDER LH
16. INSTALL VISOR HOLDER RH
17. INSTALL VISOR ASSEMBLY LH
18. INSTALL VISOR ASSEMBLY RH
19. INSTALL FRONT PILLAR GARNISH LH
20. INSTALL FRONT PILLAR GARNISH RH
21. INSTALL ROOM NO. 1 LIGHT ASSEMBLY
22. INSTALL ASSIST GRIP SUB-ASSEMBLY
23. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP LH
24. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP RH
25. INSTALL INNER REAR VIEW MIRROR ASSEMBLY
26. CHECK FOR LEAKS AND REPAIR
a. Conduct a leak test after the adhesive has completely hardened.
b. Seal any leaks with auto glass sealer.
27. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL