Removal and Installation

WINDSHIELD GLASS

REMOVAL

CAUTION:
- Wear gloves to remove and install the windshield glass.
- Use seat covers to avoid damaging any surfaces.

1. To remove the windshield first remove the following parts:
1. Inside rear view mirror
2. Wiper arms
3. Cowl top cover
4. Front pillar trims
5. Sun visors and assist handles
6. Cowl top cover pad

2. Peel off the molding and remove the windshield glass spacer.






NOTE: When molding removal is difficult, cut the molding with a knife

3. Pull down the front of the headliner.
4. In order to protect the body (paint surface), apply cloth tape to all body grease around the installed windshield glass.
5. Use the special tool (09861-31100) to cut through the sealant.






6. Make mating marks on the glass and body if the glass is to be reinstalled.

NOTE: Use chalk or equivalent to make mating marks on the glass and body.






7. Take out the windshield glass with the special tool (09861-31400).






INSTALLATION

1. Using a knife or the special tool (09861-31200), cut the old sealant smoothly to a thickness of about 2 mm (0.08 in.) on the bonding surface around the entire windshield flange

CAUTION: Be careful not to remove more adhesive than necessary, and also not to damage the paintwork on the body surface with the knife. If the paintwork is damaged, repair the damaged area with touch-up-paint






2. Clean the body bonding surface with a sponge dampened in alcohol, or wax and grease remover.
3. When reusing the glass, remove the adhesive still adhered to the glass, and clean with isopropyl alcohol. Clean the body side in the same way.

CAUTION: Let the cleaned areas stand for 1 minute or more, and carry out the next procedures after they have dried. Also, don't touch any surface that has been cleaned.

4. Install the windshield glass spacer at the locations as shown in illustration.






5. When replacing the glass, temporarily set the glass against the body, and place mating marks on the glass and body.
Use unleaded petrol to degrease the inside and outside of the windshield glass and the body flanges.






6. Evenly apply a light coat of glass primer to the windshield glass and then let it dry for 1 to 15 minutes.






NOTE:
1. Do not apply body primer to the glass. The primer strengthens the adhesive, so be sure to apply it evenly around the entire circumference.
2. The primer strengthens the adhesive, so be sure to apply it evenly around the entire circumstance
Also, a too thick application will weaken the adhesive.
3. Never touch the primed surface with your hands. If you do, the adhesive may not bond to the glass properly, causing a leak after the windshield glass is installed.
4. Keep water, dust, and abrasive materials away from the primer.

7. Glue the rubber dam to the inside surface of the windshield glass around the edge as shown, to contain the sealant during installation.






8. Apply a light coat of body primer to the original sealant remaining around the window opening flange. The glass should be installed 10 minutes after you apply the primer.






9. Pack adhesive into the cartridge avoiding air pockets, to ensure continuous application. Put the cartridge in a caulking gun or sealant gun.and run a bead of adhesive around the edge of the glass.






N0TE: Apply the adhesive within 5 minutes after applying the primer.

10. Using the suction cups or the special tool (09861-31400), lower the glass over the opening align it with the marks made in step 5 and set it down on the sealant, insert two lower spacers to prevent the windshield from moving downward.






11. Align marks of the windshield glass molding (white point in the glass molding) and inside roof molding.






12. Press the glass molding from center of the car to the left pillar and right pillar simultaneously.
13. After one hour, perform a water-leak test for the windshield. Use a cold water spray, being careful not to direct a powerful stream of water on the new adhesive material. Allow water to spill over the edges of the glass.
14. If there are leaks, dry the affected area, then apply sealant.






NOTE:
- Let the car stand for at least four hours after windshield installation. If the -car has to be used within the first 8 hours, it must be driven slowly.
- Keep the windshield dry for the first hour after installation.

15. Install the removed parts.

NOTE: Advise the customer not to do the following for two to three days:
- Slam the doors with all the windows rolled up.
- Stress the body excessively (such as when going in and out of driveways at an angle or driving over rough, uneven roads).