Windshield: Service and Repair

Windshield

Parts Location:

Removal

1. Disconnect the battery ground cable.
2. Remove the windshield wiper arm assembly.
3. Remove the cowl cover.
- Remove the three clips and five fixing screws.

4. Remove the windshield side molding.
- Pull the molding out from the windshield side molding clip.

5. Remove the windshield support.
6. Remove the windshield upper molding.
7. Remove the front pillar trim cover.
8. Remove the sun visors and sun visor holders.
9. Remove the rear view mirror.
- Disconnect the connector (1).
- Turn the channel mount (2) 90° clockwise and pull down.







10. Remove the windshield (3).
- Use a knife or a pick to make a hole in part of the adhesive caulking material
- Secure one of a piece of steel piano wire (4) (0.6 mm/0.02 inches diameter) to a piece of wood (1) that can serve as a handle.
- Use a pair of needle nose pliers to insert the other end of the piano wire through 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.

CAUTION: Apply an adhesive cloth tape (2) to the edge of the vehicle body to protect the coated surface. Pay attention to the spacers given at 10 positions of the glued part.







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

11. Remove the spacer.

Installation

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 (1).
- Peel off the adhesive tape (2) from the windshield upper molding, and start applying it with one end of the glass (3) 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. Install the windshield (1).
- Apply primer (6) (Sun star #435-40 or equivalent) to the windshield side bonding surface as shown in the figure.
- Apply primer (4) (Sun star #435-95 or equivalent) to the body side bonding surface as shown in the figure.
- Allow curing time of at least 3 minutes after application of the primer before applying adhesive.

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:
- Use the adhesive manufactured 3 months or less ago.
- Wipe off adhesive stains on positions other than requires application.
- Stir the adhesive for a minute or more before use.







- After drying primer completely, apply a sealing adhesive (1) (Sun star #555 or equivalent) along the edge of the glass so that the sealing adhesive has a 20 mm (0.79 in) junction at middle of the base of the glass.








- Set the windshield(3) with sealing adhesive applied along its edge in the body panel. Specifically, adjust windshield support (4) with the upper molding (2) making contact with the body panel (1), press the glass, and tighten the windshield support.







6. Install the rear view mirror and connect the connector.
7. Install the sun visor and sun visor holders.
8. Install the front pillar trim cover.
9. Install the windshield side molding.
- Let the upper side of the side molding make contact with the upper molding so that the side molding is put upon the upper molding.

10. The lower side is inserted in the fender panel.
11. Install the cowl cover.
12. Install the wiper arm assembly.
- Cure the adhesive at the temperature of 20 - 30 °C (68 - 86 °F) for 24 hours.
- Check that the windshield does not leak water.