Windshield: Service and Repair

Windshield

Parts Location:

Removal

1. Disconnect the battery ground cable.
2. Remove the front pillar trim cover.
- Turn up the finisher and pry the trim cover clips free from the body panel.

3. Remove the sunvisors and sunvisor holders.
4. Remove the rear view mirror.
- Disconnect the connector (1).
- Turn the channel mount (2) 90 degrees clockwise and pull down.







5. Remove windshield wiper arm.
6. Remove windshield side molding.
- Pull the molding out from drip rail.

7. Remove front cowl cover.
8. Remove windshield support.
9. Remove upper moulding.
10. Remove windshield.
- Use a knife to cut through part of the adhesive caulking material.
- Secure one end of a piece of steel piano wire (0.02 inches in diameter) to a piece of wood that can serve as a handle.
- Use a pair of needle nose pliers to insert the other end of the piano wire through the adhesive caulking material at the edge of the windshield glass.
- Secure the other end of the piano wire to another piece of wood.
- With the aid of an assistant, carefully move the piano wire with a sawing motion to cut through the adhesive caulking material around the entire circumference of the windshield glass.
- Attach some cloth tape (1) on the body for protecting the painting surface.







- Clean the remaining adhesive caulking material from the area of the body which holds the windshield.

Installation

To install, follow the removal steps in the reverse order, noting the following points:

1. Clean the bonding surfaces of both the windshield and body panel with a soft rag and white gasoline.
2. Install the spacer.
- Attach spacers in ten locations as shown in the figure.
- Always use new spacer.







3. Install the windshield upper molding.
- Peel off the tear-away paper from the windshield upper molding and start applying it with one end of the glass and cut away the surplus at the other end of the glass for length adjustment.
- Always use new upper molding.

4. Temporary install the windshield support.
5. Apply the primer (3) to the windshield and body panel.
- Apply the primer (3) (Sun star #435-40 or equivalent) to the windshield side bonding surface as shown in the figure.
- Apply the primer (Sun star #435-95 or equivalent) to the body side bonding surface.

NOTE: Apply an adhesive 3 minutes or more but within 24 hours after the application or primer. more than 24 hours have passed, reapply primer.

Primer should be handled as following:
1. Use the primer manufactured 3 months or less ago and having been kept in a refrigerator.
2. Wipe off primer-stains on positions other than requires application.
3. Stir the primer for a minute or more before use.







6. Apply the adhesive (1) to the windshield.
- After drying primer completely, apply a sealing adhesive (Sun star #555 or equivalent) along the edge of the glass so that the sealing adhesive has a 2.0 mm (0.79 in) junction at middle of the base of the glass.







NOTE: Apply an adhesive 3 minutes or more but within 24 hours after the application of primer. If more than 24 hours have passed, reapply primer.

Adhesive should be handled as follows:
1. Use the adhesive manufactured 3 months or less ago.
2. Wipe off adhesive-stains on positions other than requires application.

7. Install the windshield.
- Set the windshield with sealing adhesive applied to entire circumference in the body panel. Specifically, adjust the windshield support with the upper molding making contact with the body panel, press the glass and tighten the windshield support.

NOTE: Affix the glass within 5 minutes of application.







8. Install the front cowl cover.
9. Install side molding.
- Use white gasoline and a soft cloth to wipe away any excess adhesive.
- Cure the bonding at a temperature of 20 degrees C -30 degrees C (68 degrees F -86 degrees F) for 24 hours.
- Check that the windshield does not leak water.







10. Install windshield wiper arm.