Windshield: Service and Repair

Removal and Installation






Windshield Removal






1. To protect the body (paint surface), apply cloth tape to all body areas around the installed.
2. Using piano wire
1. Using a sharp-point drill, make a hole in the windshield adhesive.
2. Pass the piano wire from the inside of the vehicle through the hole.
3. Using a sharp-point drill, make a hole in the windshield adhesive.
4. Pass the piano wire from the inside of the vehicle through.

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

5. Pull the piano wire alternately from the inside and outside along the windshield to cut the adhesive.
3. Using glass adhesive knife
1. Get glass adhesive knife.

Caution: Putting glass adhesive knife too deeply into windshield adhesive may damage windshield.






2. Keep glass adhesive knife at right angles with the windshield edge, and put the blade at the windshield edge and surface. Then cut away adhesive along the windshield edge.






4. Make mating marks on the windshield and body.
5. Use special tool MB990480 to remove the windshield.






Caution:
- Be careful not to remove more adhesive than is necessary.
- Be careful also not to 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.

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

Caution: Allow the cleaned area to dry for at least three minutes. Do not touch any surface that has been cleaned.

8. When reusing the windshield, remove the adhesive still adhering to the windshield, and clean with 3M AAD Part number 8906 or equivalent.
9. Clean the body side in the same way.

Installation Service Point

Windshield Upper Molding/Glass Stopper/Windshield Spacer/Spacer/ Windshield Installation

1. When replacing the windshield, temporarily set the windshield against the body, and place a mating mark on the windshield and body.
2. Use 3M AAD Part number 8906 or equivalent to de grease the inside and outside of the windshield and the body flanges.

Caution:
- The primer strengthens the adhesive, so be sure to apply it evenly around the entire circumference. However, a too thick application will weaken the adhesive.
- Do not touch the coated surface.

3. Soak a sponge in the primer, and apply evenly to the windshield and the body in the specified places.
4. Apply the primer, and then let it dry for 3 to 30 minutes, depending on the ambient temperature and humidity.
5. Install the windshield upper molding to the windshield.
6. Install the glass stopper to the windshield.
7. Place the window spacer to the windshield so that it inclines toward the windshield and its right and ;eft clearances are equal. Then install the spacer firmly so that it is firmly anchored.










8. Fill a sealant gun with adhesive. Then apply the adhesive evenly around the windshield within 30 minutes after applying the primer.

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

9. Align the mating marks on the windshield and the body, and lightly press the windshield evenly so that it adheres completely.
10. Use a spatula or similar tool to remove any excessive adhesive. Clean the surface with 3M AAD Part number 8906 or equivalent. Avoid moving the vehicle until the adhesive sets.

Caution:
- Do not move the vehicle unless absolutely necessary.
- When testing for water leakage, do not pinch the end of the hose to spray water.

11. Wait 30 minutes or more, and then test for water leakage.