Windshield Removal and Installation
Windshield Removal and Installation
Windshield Components
Preparation
Removal
1) Clean inside, outside and around glass.
2) Remove wiper arms. Wiper Motor Removal and Installation
3) Remove cowl top garnish.
4) Using masking tape, cover body surface around glass to prevent any damage when cutting the adhesive.
5) Remove rear view mirror. Rear View Mirror Removal and Installation
6) Remove rain / light sensor. Removal and Replacement
7) Remove instrument panel, if necessary. Removal and Replacement
8) Remove roof lining, if necessary. Service and Repair
9) Remove or cut windshield molding.
10) Make hole into adhesive with eyeleteer (1) and pass piano string through it.
11) Cut all adhesives of windshield (1) with piano string (2).
NOTE:
If piano string contacts the vehicle body or the instrument panel when cutting the windshield adhesive with it, the vehicle body and/or instrument panel may be damaged.
Use piano string by keeping it as close to windshield glass as possible.
12) Using knife (1), smoothen adhesive remaining (2) on body side (3) and thickness of adhesive should be 1 to 2 mm (0.04 to 0.08 in.).
NOTE:
If windshield is to be reused, be careful to remove adhesive (1) not to damage primer application surface (2).
NOTE:
Before using knife (1), degrease it with alcohol or the like.
Installation
NOTE:
For proper handling and drying time of primer and adhesive, refer to their maker's instruction.
1) Install two new glass upper fasteners (female) (1) to the body (2).
2) Align glass upper fasteners (male) on windshield (1) with glass upper fasteners (female) and temporarily position the windshield (1) on body so that clearances at right and left sides of it and body are equal.
Then put alignment marks (3) on windshield (1) and body (2).
3) Clean contact surfaces of old adhesive (4) left on body. Apply primer (2) where paint or bare metal is exposed (3).
NOTE:
Do not apply primer on adhesive.
4) Clean area about 30 to 50 mm (1.18 to 1.97 in.) from the edge of windshield with gauze and white gasoline. Dry white gasoline for 10 minutes or more.
5) Apply primer onto windshield molding mounting area on windshield (2) and install new windshield molding (3) to windshield.
6) Install new spacers (1) to windshield.
7) Apply primer to adhesive application area on windshield.
NOTE:
Do not touch primer-coated surface.
Width of primer on windshield
"a": 17 mm (0.67 in.)
"b": 15 mm (0.59 in.)
"c": 18 mm (0.71 in.)
8) Apply adhesive (1) as shown in figure.
NOTE:
- Attach windshield (2) on body within 5 minutes from applying adhesive.
- Use rubber sucker grip to carry glass after adhesive is applied.
Adhesive amount and application area on windshield
Width of adhesive "a": Approx. 7.0 mm (0.28 in.)
Height of adhesive "b": Approx. 15.0 mm (0.59 in.)
Application area "c": Approx. 11.6 mm (0.46 in.), "d": Approx. 12.2 mm (0.48 in.), "e": Approx. 36.7 mm (1.44 in.)
9) Holding windshield (3) with rubber sucker grips (1), align glass upper fasteners (male) (2) with glass upper fasteners (female) (4), align alignment marks put in Step 2) and install windshield (3).
10) Dry adhesive.
NOTE:
Adhesive requires a minimum hardening time, which varies with the type of the adhesive used. If proper precautions are not taken during this hardening time, problems such as poor sealing, loosening, and detachment of the windshield glass can occur.
- Avoid quickly closing a door before complete hardening of the adhesive. Closing a door quickly could cause the windshield glass to become loose or even come off. If a door must be closed before the adhesive hardens completely, open all side windows first and then gently close the door.
- If molding is not securely in place, hold it down with tape until the adhesive completely hardens.
- Be sure to check the hardening time of the adhesive used and observe the precautions to take during the hardening time.
- Refrain from driving until the adhesive completely hardens.
- Do not blow compressed air directly at adhesive applied part when drying.
- Do not use infrared light or like for drying.
11) Check for water leakage 1 or 2 hours after installing windshield. If leakage is found, remove and install windshield again.
NOTE:
Doing water leakage check using water at too high a pressure may cause the adhesive to get detached.
Use water flowing from a hose without pressurizing it to check for water leakage.
12) Install roof lining. Service and Repair
13) Install instrument panel if it has been removed. Removal and Replacement
14) Install rear view mirror. Rear View Mirror Removal and Installation
15) Install cowl top garnish.
16) Install wiper arms. Wiper Motor Removal and Installation