Windshield: Service and Repair
WINDSHIELD REMOVAL1. Remove the rearview mirror.
2. Remove the cowl grille.
3. Remove the headliner.
4. Apply protective tape along the edge of the body to protect it from damage.
5. Apply protective tape to the dashboard to protect it from damage.
6. Cut the lip of the windshield molding using a razor.
WARNING: Using a razor with bare hands can cause injury. Always wear gloves when using a razor.
NOTE: The windshield molding is a replacement part.
Not Reusing Windshield
1. Remove the base.
NOTE: For the areas of the sealant that are difficult to cut, use the SST (piano wire) and follow the procedure under "Reusing Windshield".
2. Use the tool like that shown in the figure, and insert the blade into the sealant.
3. Pull through the sealant around the edge of the glass.
4. Remove the windshield.
Reusing Windshield
NOTE: Before removing the windshield from the body, mark the position of the windshield by affixing tape to the windshield and body panel.
1. Make a hole through the sealant, avoiding pins, from the inside of the vehicle using an awl.
2. Pass the SST (piano wire) through the hole.
WARNING: Using the SST (piano wire) with bare hands can cause injury. Always wear gloves when using the SST (piano wire).
3. Wind each end of the SST (piano wire) around a bar.
NOTE: Use a long sawing action to spread the work over the whole length of the SST (piano wire) to prevent it from breaking due to localized heating.
4. Fix one end of the SST (piano wire), and while pulling the other end, cut the sealant around the windshield.
5. Remove the windshield.
6. Remove the pins from the windshield.
7. Remove the windshield molding from the windshield glass.
WINDSHIELD INSTALLATION
CAUTION: To prevent the sealant from cracking or the glass from being pushed out by air pressure if a door is closed, open all of the windows and leave them open until the sealant has hardened.
1. Cut away the old sealant using a razor so that 1-2 mm (0.04-0.07 in} thickness of sealant remains along the perimeter of the frame.
WARNING: Using a razor with bare hands can cause injury. Always wear gloves when using a razor.
2. If the sealant has come off completely in any one place, apply some primer after degreasing, and allow it approx. 30 min to dry. Then put on new sealant to create a 2 mm (0.08 in) layer.
3. Clean and degrease an approx. 50.0 mm (1.97 in) wide strip along the perimeter of the glass and the bonding area on the body.
4. If installing reused glass, install pins at the ceramic void an the upper part of the windshield.
5. If installing reused glass, align the windshield molding marking and the center of the upper section of the windshield, then install the molding to the windshield.
6. Use only glass primer on the glass. Allow it to dry for approx. 30 min.
CAUTION: Keep the area free of dirt and grease, and do not touch the surface. Otherwise, the primer may not properly bond to the surface of the glass and body, which may cause leaks to occur.
7. Apply sealant to the area of the glass surface as shown in the figure.
8. Set the windshield in place and insert the pins into the body. Install the windshield.
9. Verify that the gap of the A-pillar part as shown in the above figure.
10. Keeping the measurement of the molding lip gap within specification, press completely along the perimeter of the glass.
11. Install the cowl grille.
12. Install the headliner
13. Install the rearview mirror.
14. Allow the sealant to harden completely.
Sealant hardening time: 24 hours