Windshield: Service and Repair
Windshield Glass:
WINDSHIELD GLASS
REPLACEMENT
HINT:
- The installation procedures are the removal procedures in reverse order. However, only installation procedures requiring additional information are included.
- A bolt without a torque specification is shown in the standard bolt chart.
1. REMOVE FRONT WIPER ARM RH
2. REMOVE FRONT 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, detach the 5 clips and remove the pillar.
HINT: Tape the screwdriver tip before use.
22. REMOVE FRONT BODY PILLAR ASSEMBLY OUTER LH
a. Remove the nut.
b. Using a screwdriver, detach the 5 clips and remove the pillar.
HINT: Tape the screwdriver tip before use.
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.
Specification (A): 5 mm (0.20 in.)
NOTE:
- Do not drill the rivet at an angle as this will cause damage to the drill and drill hole. Line up the drill and rivet, and carefully drill out the rivet head.
- Be careful as the cut rivet will be very hot.
3. Even if the flange is taken off, continue drilling and push out the remaining fragment with the drill.
24. REMOVE WINDSHIELD MOULDING OUTSIDE LH
25. REMOVE WINDSHIELD MOULDING OUTER UPPER
a. Using a knife, cut through the moulding as shown in the illustration.
NOTE: Be careful not to damage the vehicle body with the knife.
b. Remove the remaining moulding.
HINT: Make a partial cut in the moulding. Then pull and remove it by hand.
26. REMOVE WINDSHIELD GLASS
a. Apply protective tape to the outer surface of the vehicle body to prevent scratches.
b. From the interior, insert a piano wire between the vehicle body and glass as shown in the illustration.
c. Tie objects that can serve as handles (for example, wooden blocks) to both wire ends.
NOTE:
- When separating the glass from the vehicle, be careful not to damage the vehicle's paint or interior/exterior ornaments.
- To prevent the instrument panel from being scratched when removing the glass, place a plastic sheet between the piano wire and instrument panel.
d. Place matchmarks over the glass and vehicle body on the locations indicated in the illustration.
HINT: Matchmarks do not need to be placed if the glass is not going to be reused.
e. Cut through the adhesive by pulling the piano wire around the glass.
NOTE: Leave as much adhesive on the vehicle body as possible when cutting through the adhesive.
f. Detach the stoppers.
g. Using a suction cup, remove the glass.
27. CLEAN WINDSHIELD GLASS
a. Using a scraper, remove the damaged stoppers, dams and adhesive sticking to the glass.
b. Clean the outer edges of the glass with white gasoline.
NOTE:
- Do not touch the glass surface after cleaning it.
- Even if using new glass, clean it with white gasoline.
28. CLEAN VEHICLE BODY
a. Clean and shape the contact surface of the vehicle body.
1. On the contact surface of the vehicle body, use a knife to cut away excess adhesive as shown in the illustration.
HINT: Leave as much adhesive on the vehicle body as possible.
NOTE: Be careful not to damage the vehicle body.
2. Clean the contact surface of the vehicle body with cleaner.
HINT: Even if all the adhesive has been removed, clean the vehicle body.
29. INSTALL WINDSHIELD GLASS STOPPER NO.1
a. Apply Primer G to the glass where the stoppers will be installed.
NOTE:
- Allow the Primer G to dry for 3 minutes or more.
- Throw away any leftover Primer G.
- Do not apply too much Primer G.
b. Install 2 new stoppers onto the glass as shown in the illustration.
30. INSTALL WINDSHIELD GLASS RETAINER
a. Install 2 new retainers onto the glass, as shown in the illustration.
31. INSTALL WINDOW GLASS ADHESIVE DAM
a. Apply Primer G to the glass where the adhesive dams will be installed.
NOTE:
- Allow the Primer G to dry for 3 minutes or more.
- Throw away any leftover Primer G.
- Do not apply too much Primer G.
b. Remove the peeling paper from the adhesive part of the dam. Install the dam (adhesive side) to the glass (Primer G area) as shown in the illustration.
32. INSTALL WINDSHIELD MOULDING OUTER UPPER
a. Using a brush or sponge, apply Primer G to the glass where the moulding will be installed.
NOTE:
- Allow the Primer G to dry for 3 minutes or more.
- Throw away any leftover Primer G.
- Do not apply too much Primer G.
b. Install new moulding before the adhesive dries.
33. INSTALL WINDSHIELD GLASS
a. Position the glass.
1. Using a suction cup, place the glass in the correct position.
2. Check that the entire contact surface of the glass rim is perfectly even.
3. Place matchmarks over the glass and vehicle body on the locations indicated in the illustration.
HINT:
- Placing matchmarks is only necessary if the glass being installed is new. If it is reused glass, matchmarks should already be present.
- When reusing the glass, check and correct the match mark positions.
NOTE: Check that the stoppers are attached to the vehicle body correctly.
4. Using a suction cup, remove the glass.
b. Using a brush, apply Primer M to the exposed part of the vehicle body.
NOTE:
- Allow the Primer M to dry for 3 minutes or more.
- Do not apply Primer M to the adhesive.
- Throw away any leftover Primer M.
- Do not apply too much Primer M.
c. Using a brush or sponge, apply Primer G to the contact surface of the glass.
HINT: If Primer G is applied to an area that is not specified, apply white gasoline to a clean cloth and wipe off the excess primer.
NOTE:
- Allow the Primer G to dry for 3 minutes or more.
- Throw away any leftover Primer G.
- Do not apply too much Primer G.
d. Apply adhesive to the glass.
Adhesive: Part No. 08850-00801 or equivalent
1. Cut off the tip of the cartridge nozzle as shown in the illustration.
HINT: After cutting off the tip, use all adhesive within the time written in the table.
2. Load the sealer gun with the cartridge.
3. Coat the glass with adhesive, as shown in the illustration.
e. Install the glass to the vehicle body.
1. Using a suction cup, position the glass so that the matchmarks are aligned. Press it in gently along the rim.
2. Lightly press the front surface of the glass to ensure that it is securely fit to the vehicle body.
NOTE:
- Check that the stoppers are attached to the vehicle body correctly.
- Check that the vehicle body and glass have a small gap between them.
3. Hold the glass in place securely with protective tape or equivalent until the adhesive hardens.
4. Using a scraper, remove any excess or protruding adhesive.
HINT: Apply adhesive on the glass rim.
NOTE: Do not drive the vehicle for the amount of time written in the table.
34. INSTALL WINDSHIELD MOULDING OUTSIDE RH
a. Using an air riveter or hand riveter with nose piece, strike rivets into the body panel.
NOTE:
- Do not pry the rivet with the riveter, as this will cause damage to the riveter and mandrel.
- Confirm that the rivets are seated properly against the moulding outside.
- Do not tilt the riveter when installing the rivet to the moulding outside.
- Do not leave any space between the rivet head and the moulding outside.
- Do not have any space between the moulding outside and body panel. Firmly hold together the 2 items while installing the rivet.
35. INSTALL WINDSHIELD MOULDING OUTSIDE LH
36. INSTALL FRONT BODY PILLAR ASSEMBLY OUTER RH
a. Replace the clip with a new one.
b. Install the front right body pillar assembly outer with 5 clips and nut.
37. INSTALL FRONT BODY PILLAR ASSEMBLY OUTER LH
38. CHECK FOR LEAKS AND REPAIR
a. Conduct a leak test after the adhesive has completely hardened.
b. Seal any leaks with auto glass sealer.