Windshield: Service and Repair
REMOVALHINT: Tape the screwdriver tip before using it to pry parts
1. REMOVE WIPER ARMS
Remove the wiper arm head cap, 2 nuts and 2 wiper arms
2. REMOVE COWL TOP VENTILATOR LOUVER
a. Remove the 5 screws and 6 clips
b. Using screwdriver, remove the cowl top ventilator louver
3. REMOVE REMOVABLE ROOF HOOK
Remove the 2 screws and removable roof hook
4. REMOVE FRONT PILLAR GARNISHES
a. Using screwdriver, remove the front pillar garnish
b. Employ the same manner described above to the other side
5. REMOVE SUN VISORS
Remove the 4 screws and sun visors
6. REMOVE MAP LIGHT ASSEMBLY
a. Using screwdriver, move the map light cover
b. Remove the 2 screws and map light assembly, then disconnect the connector
7. REMOVE FRONT ROOF HEADLINING TRIM
Using screwdriver, remove the front roof headlining
8. REMOVE INNER REAR VIEW MIRROR ASSEMBLY
9. REMOVE WINDSHIELD OUTSIDE MOULDING
a. Using a knife, cut off the moulding as shown in the illustration
NOTE: Do not damage the body with the knife.
b. Remove the remaining moulding
10. REMOVE WINDSHIELD GLASS
a. Insert piano wire between the body and glass, let it pass through
b. Tie both wire ends to wooden blocks or similar objects
NOTE: Be careful not to damage the wire harness
c. Cut the adhesive by pulling the piano wire around it
NOTE: When separating the glass, take care not to damage the paint end exterior ornaments. To prevent the safety pad from being scratched when removing the windshield, place plastic sheet between the piano wire and safety pad.
HINT: Apply protective tape to the outer surface to keep the surface from being scratched
d. Remove the glass
NOTE: Leave the adhesive on the body as much as possible when cutting off the glass.
INSTALLATION
1. CLEAN AND SHAPE CONTACT SURFACE OF BODY
a. Using a knife, cut away any rough areas on the body
HINT: Leave the adhesive on the body as much as possible
b. Clean the cut surface of the adhesive with shop rag saturated in cleaner
HINT: Even if all the adhesive has been removed, clean the body
2. CLEAN REMOVED GLASS
a. Remove the damaged No.2 stoppers and dams
b. Using scraper, remove the adhesive sticking to the glass
c. Clean the glass with cleaner
NOTE:
- Be careful not to damage the glass
- Do not touch the glass face after cleaning it
3. INSTALL NEW NO.1 STOPPERS
Attach new stoppers to the glass so that the ceramic notches on the glass will align with the stoppers as shown in the illustration
HINT: Make sure that the stoppers are installed facing the correct direction
4. INSTALL NEW DAMS
Install new dams with a double-stick tape as shown in the illustration
5. POSITION GLASS
a. Place the glass in the correct position.
b. Check that all contacting parts of the glass rim are set perfectly even.
c. Place reference marks on the glass and body.
d. Remove the glass.
6. CLEAN CONTACT SURFACE OF GLASS
Using cleaner, clean the contact surface which is black-colored area around the entire glass rim.
NOTE: Do not touch the glass face after cleaning it.
7. COAT CONTACT SURFACE OF BODY WITH PRIMER "M"
Using brush, apply Primer M to the exposed part of the body on the vehicle side.
NOTE:
- Allow 3 minutes or more to dry the primer coated surface
- Do not apply Primer M to the adhesive
- Do not keep any of the once opened Primer M for later use
8. COAT CONTACT SURFACE OF GLASS WITH PRIMER "G"
a. Using brush or sponge, coat the edge of the glass and the contact surface with Primer G as shown in the illustration
b. When the primer is applied inappropriate to the area other than the specified, wipe it off with clean shop rag before the primer dries.
NOTE:
- Allow 3 minutes or more to dry the primer coated surface
- Do not keep any of the once opened Primer G for later use
9. APPLY ADHESIVE
a. Cut off the tip of the cartridge nozzle
Part No 08850-00801 or equivalent
HINT: After cutting off the tip, use all adhesive within the time described in the table.
b. Load the sealer gun with the cartridge
c. Coat the glass with adhesive as shown in the illustration
10. INSTALL WINDSHIELD GLASS AND MOULDING
a. Install the glass, aligning the reference marks using suction rubber
HINT: Check that the stoppers are attached to the body correctly.
b. Lightly press the glass front surface
c. Correct insufficient or protruded adhesive agent using spatula
HINT: Apply the adhesive agent up to the windshield glass edge.
d. Install new windshield moulding to the windshield glass before the adhesive agent hardens
HINT: Install the moulding, aligning the center of moulding with the center of the body
e. Remove any excessive adhesive agent before it hardens
f. Hold the glass and moulding in place securely with protective tape or equivalent until the adhesive hardens
NOTE: Be sure not to drive the vehicle during the time described in the table.
11. INSPECT FOR LEAK AND REPAIR
NOTE: Conduct leak test after the hardening time has elapsed
12. INSTALL INNER REAR VIEW MIRROR
13. INSTALL FRONT ROOF HEADLINING TRIM
14. INSTALL MAP LIGHT ASSEMBLY
15. INSTALL SUN VISORS
16. INSTALL FRONT PILLAR GARNISHES
17. INSTALL COWL TOP VENTILATOR LOUVER
HINT: Check that the 6 clips on the back side of the cowl louver are surely fixed to the body
18 INSTALL WIPER ARMS
a. Operate the wiper motor once and turn the wiper switch OFF
b. Install the wiper arms and tighten the nuts by hand
c. Adjust the installation positions A of the wiper arms as shown in the illustration
A: 25 - 40 mm (0.98 - 1.57 in)
d. Torque the nuts
Torque: 20 N.m (200 kgf.cm, 15 ft.lbf)
e. Install the wiper arm head cap