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 INNER REAR VIEW MIRROR STAY HOLDER COVER
20. REMOVE INNER REAR VIEW MIRROR ASSEMBLY
21. 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.
22. REMOVE FRONT BODY PILLAR ASSEMBLY OUTER LH
23. 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.
24. REMOVE FRONT PILLAR GARNISH OUTER LH
25. 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.
26. 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.
27. CLEAN WINDSHIELD GLASS
a. Clean the outer circumference of the glass with white gasoline.
NOTE: Do not touch the glass surface after cleaning it.
28. 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.)
29. INSTALL WINDSHIELD GLASS RETAINER
a. Install 2 new retainers onto the glass as shown in the illustration.
30. INSTALL WINDOW GLASS ADHESIVE DAM
a. Install new dam with double-stick tape all the way around the glass except where the dam is installed, as shown in the illustration.
31. INSTALL WINDSHIELD MOULDING OUTER UPPER
a. Using a brush, coat the exposed part of the body on the vehicle side with Primer M.
NOTE:
- Dry the primer coating 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.
b. Using a brush or sponge, coat the edge of the glass and the contact surface with Primer G.
c. Install the windshield moulding outer upper.
32. INSTALL WINDSHIELD GLASS
a. Clean and shape the contact surface of the vehicle's body.
1. Using a knife, cut away any rough adhesive on the contact surface of the body to shape the surface.
HINT: Leave as much adhesive on the body as possible.
2. Clean the contact surface of the body with a piece of shop rag saturated with cleaner.
HINT: Even if all the adhesive has been removed, clean the body.
b. Position the glass.
1. Using a suction rubber, place the glass in the correct position.
2. Check that the whole contact surface of the glass rim is perfectly even.
3. Place reference marks between the glass and body.
NOTE: Check that the stoppers are attached to the body correctly.
HINT: When reusing the glass, check and correct the reference mark's positions.
4. Remove the glass.
c. Using a brush, coat the exposed part of the body on the vehicle side with Primer M.
NOTE:
- Dry the primer coating 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.
d. Using a brush or sponge, coat the edge of the glass and the contact surface with Primer G.
HINT: If the area other than the specified is coated by accident, wipe off the primer with a clean shop rag before it dries
NOTICE:
- Dry the primer coating for 3 minutes or more.
- Do not keep any of the opened Primer G for later use.
e. Apply adhesive.
1. Cut off the tip of the cartridge nozzle as shown in the illustration.
Part No. 08850-0801 or equivalent
HINT: After cutting off the tip, use all adhesive within the time described in the table.
2. Load the sealer gun with the cartridge.
3. Coat the glass with adhesive, as shown in the illustration.
f. Install the glass.
1. Using a suction rubber position the glass so that the reference marks are aligned. and press it in gently along the rim.
NOTE:
- Dry the primer coating for 3 minutes or more.
- Check that the stoppers are attached to the body correctly.
- Check the clearance between the body and glass.
2. Lightly press the glass front surface for close contact.
3. Using a scraper remove any excess or protruding adhesive.
HINT: Apply adhesive on the glass rim
NOTE: Take care not to drive the vehicle during the time described in the table.
33. 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.
- If the trigger is pulled, it may damage SST.
NOTE:
- Do not prize a riveter, because the riveter will be damaged and the mandrel will be bent.
- Do not tilt the riveter when removing the rivet, because the materials are not tightened firmly.
- Install the rivet while attaching the materials, because they are not tightened firmly.
34. INSTALL WINDSHIELD MOULDING OUTSIDE LH
35. INSTALL FRONT BODY PILLAR ASSEMBLY OUTER RH
a. Exchange the clip for a new one.
b. Install the front right body pillar assembly outer with 5 clips and nut.
36. INSTALL FRONT BODY PILLAR ASSEMBLY OUTER LH
37. INSPECT FOR LEAKS AND REPAIR
a. Conduct a leak test after the hardening time has elapsed.
b. Seal any leaks with auto glass sealer.