Windshield: Service and Repair
Windshield Glass:
WINDSHIELD GLASS
REPLACEMENT
1. REMOVE FR WIPER ARM RH
2. REMOVE FR WIPER ARM LH
3. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY
4. REMOVE DOOR SCUFF PLATE ASSEMBLY RH
5. REMOVE DOOR SCUFF PLATE ASSEMBLY LH
6. REMOVE FRONT DOOR OPENING TRIM COVER RH
7. REMOVE FRONT DOOR OPENING TRIM COVER LH
8. REMOVE FRONT PILLAR GARNISH RH
9. REMOVE FRONT PILLAR GARNISH LH
10. REMOVE VISOR BRACKET COVER RH
11. REMOVE VISOR BRACKET COVER LH
12. REMOVE RH VISOR ASSEMBLY
13. REMOVE LH VISOR ASSEMBLY
14. REMOVE VISOR HOLDER
15. REMOVE MAP LAMP ASSEMBLY
16. REMOVE ROOF FRONT CORNER HEADLINING RH
17. REMOVE ROOF FRONT CORNER HEADLINING LH
18. REMOVE ROOF HEADLINING ASSEMBLY
19. REMOVE FRONT BODY PILLAR ASSEMBLY OUTER RH
a. Remove the nut.
b. Using a screwdriver, remove the front body pillar assembly outer.
HINT: Tape the screwdriver tip before use.
c. Employ the same manner described above to the other side.
20. REMOVE FRONT BODY PILLAR ASSEMBLY OUTER LH
21. REMOVE WINDSHIELD MOULDING OUTSIDE RH
a. Remove the clip.
b. Remove the 3 rivets.
1. Use a drill of less than Dia 4 mm (0.16 in.).
2. Gently and vertically place the drill tip onto the rivet, and cut the rivet flanges.
A: 5 mm (0.20 in.)
NOTE:
- Prizing the hole with a drill can lead to damage to the rivet hole or the drill itself.
- Be careful when undertaking this task as the cut rivet is hot.
3. Even if flange is taken off, continue drilling and push-out remaining fragment with the drill.
c. Employ the same manner described above to the other side.
22. REMOVE FRONT PILLAR GARNISH OUTER LH
23. REMOVE WINDSHIELD MOULDING OUTER UPPER
a. Using a knife, cut off the moulding as shown in the illustration.
NOTE: Do not damage the body with the knife.
b. Remove the remaining moulding.
24. REMOVE WINDSHIELD GLASS
a. Push a piano wire through between the body and glass from the interior.
b. Tie both wire ends to wooden blocks or similar objects.
HINT: Apply protective tape to the outer surface to keep the surface from being scratched.
NOTE: When separating the glass, take care not to damage the paint and interior and exterior ornaments. To prevent scratching the safety pad when removing the windshield, place a plastic sheet between the piano wire and safety pad.
c. Cut the adhesive by pulling the piano wire around it.
d. Remove the glass.
NOTE: Leave as much adhesive on the body as possible when cutting off the glass.
25. CLEAN WINDSHIELD GLASS
a. Clean the outer circumference of the glass with white gasoline.
26. INSTALL WINDSHIELD GLASS STOPPER NO.1
a. Install 2 new stoppers onto the glass as shown in the illustration.
A: 40 mm (1.57 in.)
B: 8 mm (0.31 in.)
27. INSTALL WINDSHIELD GLASS RETAINER
a. Install 2 new retainers onto the glass as shown in the illustration.
28. INSTALL WINDOW GLASS ADHESIVE DAM
a. Install 2 new dams with double-stick tape all the way around of the glass except where the dam is installed, as shown in the illustration.
a: 7 mm (0.28 in.)
b: 45 mm (1.78 in.)
29. INSTALL WINDSHIELD GLASS
a. Place the glass in the correct position.
b. Check that all contacting parts of the glass rim are perfectly even and do not make contact with the fasteners.
c. Place reference marks between the glass and body.
d. Remove the glass.
e. Using a knife, cut away any rough areas on the body.
HINT: Leave as much adhesive on the body as possible.
f. 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.
g. Using a brush, coat an exposed part of the body on the vehicle side, with Primer M.
NOTE:
- Let the primer coating dry for 3 minutes or more.
- Do not coat the adhesive with Primer M.
- Do not keep any of the opened Primer M for later use.
h. Using a brush or sponge, coat the edge of the glass and the contact surface with Primer G.
i. When an unspecified area is coated with the primer, 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.
j. Cut off the tip of the cartridge nozzle.
k. Load the sealer gun with the cartridge.
l. Coat the glass with adhesive, as shown in the illustration.
A: 12 mm (0.47 in.)
B: 8 mm (0.31 in.)
30. INSTALL WINDSHIELD MOULDING OUTSIDE RH
a. Using an air riveter or hand riveter with nose piece, strike rivets into the body panel.
NOTE:
- If the rivet is not positioned perpendicularly it will bend the mandrel.
- When trigger is pulled, it may damage SST.
31. INSTALL FRONT PILLAR GARNISH OUTER LH
32. INSTALL FRONT BODY PILLAR ASSEMBLY OUTER RH
a. Exchange the clip with a new one.
b. Install the front right body pillar assembly outer with clips in 5 parts and nut.
33. INSTALL FRONT BODY PILLAR ASSEMBLY OUTER LH
34. INSPECT FOR LEAK AND REPAIR
a. Conduct a leak test after the hardening time has elapsed.
b. Seal any leaks with auto glass sealer.