Windshield: Service and Repair
Windshield:
REMOVAL
1. REMOVE PART OF FRONT DOOR OPENING TRIMS
2. REMOVE ASSIST GRIPS
3. REMOVE SUN VISORS AND HOLDERS
4. REMOVE MAP LAMP ASSEMBLY
a. Using a screwdriver, remove the lens and cover.
HINT: Tape the screwdriver tip before use.
b. Remove the 4 screws and map lamp assembly.
c. Disconnect the connectors.
5. REMOVE INNER REAR VIEW MIRROR
a. Remove the cover.
b. Using a torx socket wrench, remove the bolt.
Torx wrench: T30 (part No. 09042-00010 or locally manufactured tool)
c. Remove the inner rear view mirror.
6. REMOVE FRONT PILLAR GARNISH
a. Using a screwdriver, open the cover.
HINT: Tape the screwdriver tip before use.
b. Remove the bolt.
c. Remove the front pillar garnish and cover.
d. Use the same manner described above to the other side.
7. REMOVE ROOF HEADLINING
a. w/ Sliding roof:
Remove the opening trim.
b. Remove the front portion of roof headlining.
8. REMOVE ROOF DRIP SIDE FINISH CENTER MOULDINGS
9. REMOVE WIPER ARMS
10. REMOVE WEATHERSTRIP
11. REMOVE COWL LOUVER
12. REMOVE WINDSHIELD OUTSIDE MOULDING CLIP
Using a drill of less than Dia 4 mm (0.16 in.), drill out the rivet heads as shown in the illustration.
CAUTION: The cut rivet and rivet cutter will be not, avoid touching them.
NOTE: Do not jiggle the rivet cutter while cutting, otherwise you may enlarge the rivet hole or damage the rivet cutter.
HINT: Do not drill the body.
13. REMOVE WINDSHIELD UPPER MOULDING
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.
14. REMOVE WINDSHIELD GLASS
a. Push piano wire through between the body and glass from the interior.
b. Tie both wire ends to a 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, be careful not to damage the paint, 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 of the adhesive on the body as possible when cutting off 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. INSTALL NEW 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 glass with the ceramic notch on the glass aligned with the stoppers, as shown in the illustration.
3. INSTALL NEW RETAINERS
a. Remove the damaged retainers.
b. Cut off the old adhesive around the retainers installation area.
NOTE: Be careful not to damage the body.
c. Clean the installation area.
d. Attach new retainers to the glass with the ceramic notch on the glass aligned with the retainers, as shown in the illustration.
4. CLEAN REMOVED GLASS
a. Using a scraper, remove the adhesive sticking to the glass.
b. Clean the glass with cleaner.
NOTE:
- Be careful not to damage the glass.
- Do not touch the glass after cleaning it.
5. INSTALL NEW DAMS
Install new dams with double-stick tape as shown in the illustration.
A: 6.1 mm (0.240 in.)
NOTE: Do not touch the glass surface after cleaning it.
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 surface 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.
b. Before the primer dries, wipe it off with a clean shop rag.
NOTE:
- Let the primer coating dry for 3 minutes or more.
- Do not keep any of the opened Primer M for later use.
10. APPLY ADHESIVE
a. Cut off 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.
A: 12.5 mm (0.492 in.)
B: 8.0 mm (0.315 in.)
11. INSTALL GLASS
Confirm that the dam is attached to the body panel as shown in the illustration.
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.
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. INSPECT FOR LEAK AND REPAIR
a. Conduct a leak test after the hardening time has elapsed.
b. Seal any leak with sealant.
Part No. 08833-00030 or equivalent.
13. APPLY ADHESIVE TO MOULDING INSTALLATION AREA
Apply adhesive to the moulding installation area between the glass and the body.
Part No. 08833-00030 or equivalent.
14. INSTALL WINDSHIELD UPPER MOULDING
Place a new moulding onto the body and tap it by hand.
15. INSTALL WINDSHIELD OUTSIDE MOULDING CLIP
Using an air riveter with nose piece, strike rivets into the body panel to install the windshield outside moulding clips to the body panel as shown in the illustration.
NOTE: If the rivet is not positioned perpendicularly it will bend the mandrel. When the trigger is then pulled, it may damage SST.
16. INSTALL COWL LOUVER
17. INSTALL WEATHERSTRIP
18. INSTALL WIPER ARMS
Torque: 22 N.m (220 kgf.cm, 16 ft.lbf)
19. INSTALL ROOF DRIP SIDE FINISH CENTER MOULDINGS
20. INSTALL ROOF HEADLINING
a. Install the front portion of roof headlining.
b. w/ Sliding roof:
Install the opening trim.
21. INSTALL FRONT PILLAR GARNISH
a. Install the front pillar garnish and cover.
b. Install the bolt.
Torque: 9.8 N.m (100 kgf.cm, 7 ft.lbf)
c. Close the cover.
d. Use the same manner described above to the other side.
22. INSTALL INNER REAR VIEW MIRROR
a. Install the inner rear view mirror.
b. Using a torx socket wrench, install the bolt.
Torx wrench: T30 (Part No. 09042-00010 or locally manufactured tool)
Torque: 3.7 N.m (38 kgf.cm, 33 in.lbf)
c. Install the cover.
23. INSTALL MAP LAMP ASSEMBLY
a. Connect the connectors.
b. Install the map lamp assembly with the 4 screws.
c. Install the lens and cover.
24. INSTALL SUN VISORS AND HOLDERS
25. INSTALL ASSIST GRIPS
26. INSTALL PART OF FRONT DOOR OPENING TRIMS