Windshield: Service and Repair
REMOVAL1. REMOVE FRONT PART OF FRONT DOOR OPENING TRIMS
2. REMOVE FRONT PILLAR GARNISH
a. Using a screwdriver, remove the front pillar garnish.
HINT: Tape the screwdriver tip before use.
b. Employ the same manner described above to the other side.
3. w/o Sliding roof:
REMOVE MAP LIGHT ASSEMBLY
a. Using a moulding remover, remove the lens.
b. Remove the 2 screws and map light assembly, then disconnect the connectors.
4. w/ Sliding roof:
REMOVE MAP LIGHT ASSEMBLY
a. Using a moulding remover, remove the cover.
b. Remove the 2 screws and map light assembly.
c. Disconnect the connectors.
5. REMOVE SUN VISORS
a. Remove the 2 screws and sun visor, then disconnect the connector.
b. Employ the same manner described above to the other side.
6. REMOVE SUN VISOR HOLDERS
Remove the 2 screws and 2 sun visor holders.
7. REMOVE FRONT ASSIST GRIP
a. Using a screwdriver, remove the caps.
HINT: Tape the screwdriver tip before use.
b. Remove the 2 bolts and assist grip.
8. REMOVE INNER REAR VIEW MIRROR
a. Using a moulding remover, remove the cover as shown in the illustration.
b. Remove the 2 screws and inner rear view mirror.
9. REMOVE WIPER ARMS
a. Using a screwdriver, remove the 2 wiper arm head covers.
HINT: Tape the screwdriver tip before use.
b. Remove the 2 nuts and 2 wiper arms.
10. REMOVE COWL TOP VENTILATOR LOUVER
a. Remove the hood to cowl top seal.
b. Remove the 2 clips and cowl top ventilator louver.
11. PULL DOWN FRONT PART OF ROOF HEADLINING
12. REMOVE WINDSHIELD OUTSIDE MOULDING
a. Using a knife, cut oft the moulding as shown in the illustration.
NOTE: Do not damage the body with the knife.
b. Remove the remaining moulding.
13. REMOVE WINDSHIELD GLASS
a. Push piano wire through between the body and glass from the interior.
b. Tie both wire ends to wooden blocks or similar objects.
c. w/ Front window defogger;
Disconnect the connector.
NOTE: Be careful not to damage the wire harness.
d. Cut the adhesive by pulling the piano wire around it.
NOTE: When separating the glass, take care not to damage the paint and exterior ornaments. To prevent scratching the safety pad when removing the windshield, place a plastic sheet between the piano wire and safety pad.
HINT: Apply protective tape to the outer surface to keep the surface from being scratched.
e. Remove the glass.
NOTE: Leave as much of the adhesive on the body as possible when cutting oft 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 as much of the adhesive on the body as possible.
b. Clean the cutting surface of the adhesive with a piece of 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 a 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. REPLACE NO. 1 STOPPERS
a. Remove the damaged stoppers.
b. Cut off the old adhesive around the stoppers installation area.
NOTE: Be careful not to damage the body.
c. Clean the installation area.
d. Attach new stoppers to the body with the notches on the body aligned with the stoppers as shown in the illustration.
HINT: Make sure that the stoppers are installed facing in the correct direction.
4. INSTALL NEW NO. 2 STOPPERS
Attach new stoppers to the glass with the ceramic notches on the glass aligned with the stoppers as shown in the illustration.
HINT: Make sure that the stoppers are installed facing in the correct direction.
5. INSTALL NEW DAMS
Install new dams with double-stick tape as shown in the illustration.
A: 7.0 mm (0.276 in.)
B: 35.9 mm (1.413 in.)
6. POSITION GLASS
a. Place the glass in the correct position.
b. Check that all contacting parts of the glass rim are perfectly even.
c. Place reference marks between the glass and body.
d. Remove the glass.
7. CLEAN CONTACT SURFACE OF GLASS
Using a 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.
8. COAT CONTACT SURFACE OF BODY WITH PRIMER "M"
Using a brush, coat Primer M to the exposed part of body on the vehicle side.
NOTE:
- Let the primer coating dry for 3 minutes or more.
- Do not coat Primer M to the adhesive.
- Do not keep any of the opened Primer M for later use.
9. COAT CONTACT SURFACE OF GLASS WITH PRIMER "G"
a. Using a 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 coated wrongly to the area other than the specified, wipe it off with a clean shop rag before the primer dries.
NOTE:
- Let the primer coating dry for 3 minutes or more.
- Do not keep any of the opened Primer G for later use.
10. APPLY ADHESIVE
a. Cut oft 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 cartridge into the sealer gun.
c. Coat the glass with adhesive as shown in the illustration.
A: 12.5 mm (0.492 in.)
B: 8.0 mm (0.315 in.)
11. INSTALL GLASS
a. Position the glass so that the reference marks are lined up, and press in gently along the rim.
b. Using a spatula, apply adhesive on the glass rim.
c. Use a scraper to remove any excess or protruding adhesive.
HINT: Confirm that the dam is attached to the body panel as shown in the illustration.
d. Hold the windshield glass in place securely with a protective tape or equivalent until the adhesive hardens.
NOTE: Take care not to drive the vehicle during the time described in the table.
12. APPLY ADHESIVE TO MOULDING INSTALLATION AREA
Apply adhesive to the moulding installation area between the glass and the body.
Part No. O8833-OOO3O or equivalent
13. INSTALL WINDSHIELD OUTSIDE MOULDING
Place new moulding onto the body and tap it by hand.
14. INSPECT FOR LEAK AND REPAIR
a. Conduct a leak test after the hardening time has elapsed.
b. Seal any leak with sealant.
Part No. O8833-OOO3O or equivalent
15. INSTALL FRONT PART OF ROOF HEADLINING
16. INSTALL COWL LOUVER
a. Install the cowl louver with the 2 clips.
b. Install the hood to cowl top seal.
17. INSTALL WIPER ARMS
a. Operate the wipers once and turn the wiper switch OFF.
b. Install the wiper arms and tighten the nuts by hand.
c. Adjust the installation positions of the wiper arms to the positions as shown in the illustration.
A: 20.0 mm (0.787 in.)
B: 28.0 mm (1.102 in.)
d. Install the 2 wiper arms with the 2 nuts.
Torque: 26 N.m (265 kgf.cm, 19 ft.lbf)
e. Install the 2 wiper arm head covers.
18. INSTALL INNER REAR VIEW MIRROR
a. Install the inner rear view mirror with the 2 screws.
Torque: 5.5 N.m (56 kgf.cm, 49 in.lbf)
b. Install the cover.
19. INSTALL FRONT ASSIST GRIP
a. Install the assist grip with the 2 screws.
b. Install the caps.
20. INSTALL SUN VISOR HOLDERS
Install the sun visor holders with the 2 screws.
21. INSTALL SUN VISORS
Connect the connectors, then install the sun visors with the 4 screws.
22. INSTALL MAP LIGHT ASSEMBLY
a. Connect the connectors.
b. Install the map light assembly with the 2 screws.
c. w/o Sliding roof:
Install the lens.
d. w/ Sliding roof:
Install the cover.
23. INSTALL FRONT PILLAR GARNISH
a. Install the front pillar garnish to the body.
b. Employ the same manner described above to the other side.
24. INSTALL FRONT PART OF FRONT DOOR OPENING TRIMS