Removal and Replacement After Collision
REPLACEMENT PROCEDURE OF WINDSHIELD AND REAR WINDOWThe windshield glass and rear window glass of most of Nissan's vehicles have been installed with urethane adhesive sealant.
This section shows removal and installation of the glass that is bonded with urethane adhesive sealant.
REMOVAL OF GLASS
1. REMOVAL OF RELATED PARTS
Remove moldings, wiper arms, garnishes, etc. that may be scratched. Parts to be removed may vary slightly for different makes of cars. Refer to each car's Service Manual when removing the moldings.
2. CUTTING OF URETHANE ADHESIVE SEALANT
1. PIANO WIRE METHOD
- Apply adhesive tape to outer surface to protect from scratching.
- Drill a hole large enough to pass a piano wire through.
- Pass a piano wire through the hole from inside, and tie both ends to handles made of wood.
- Pull the piano wire back and forth cutting the sealant. Remove the windshield glass.
NOTE:
1. When pulling the piano wire, the wire will heat up. Apply soapy water to the area to ease the process.
2. The cutting process will require two men, one outside and one inside.
3. During the cutting process, be careful not to scratch the body.
4. This process is often used to remove the windshield glass.
2. GLASS REMOVER KNIFE METHOD
- Apply soapy water to the area to be cut.
- Cut the sealant with the blade tip, using a pulling motion while moving parallel to the glass.
NOTE:
1. Apply plenty of soapy water to the area to be cut.
2. Be careful with the knife blade so as not to scratch the glass surface.
3. Make certain that the sealant is completely cut.
4. This method is often used to remove the rear window.
3. AIR KNIFE METHOD
- An air knife is used to cut glued windshield sealant.
- The windshield sealant is cut while the blade cuts at high frequency by air pressure.
- It is composed of five blades of different sizes.
- It allows access to areas without damaging exterior painting and moldings.
- Working inside the vehicle, just one operation is required.
- Working hours can be reduced.
4. USE OF A CUTTER KNIFE
* A cutter knife may be used to cut around the edge prior to using the windshield knife.
NOTE: Be careful not to scratch the panel.
3. REMOVAL, INSPECTION AND CLEANING OF GLASS
1. WHEN GRASS IS NOT BROKEN.
- From the outside, using glass holders, remove the glass from the forward position.
- Scrape off old adhesive.
- Use alcohol or similar cleaning solvent to clean the glass.
- Inspect the glass thoroughly for scratches and dirt.
- Remove dam rubber.
2. WHEN GLASS IS BROKEN.
- While cutting the sealant with the knife, remove pieces of broken glass.
- Small pieces should be completely removed using a vacuum cleaner.
NOTE:
1. Prior to the sealant cutting process, the instrument panel must be covered with a protective covering so as to prevent pieces of broken glass from falling into the defroster duct.
2. At the time when the glass was broken, some pieces may have entered the defroster duct and heater. Carefully inspect and remove them, if found.
3. When removing glass, do not hold only one side. Use glass holders and apply an even force to remove the glass.
4. GLASS STORAGE
- The glass has a curved shape. When storing, place the glass on top of a cloth or a pad that has a similar curvature.
NOTE: Do not store the glass leaning on its corners.
INSTALLATION OF GLASS
1. REMOVAL OF FASTENER AND SCRAPING OF SEALANT
- Remove the fastener by heating [approximately 40 degrees C (1 04 degrees F)] the fastener mounting.
- Smooth the body side sealant with a knife or similar tool. Clean the re-adhesive surface with alcohol or similar cleaning solvent.
NOTE:
1. Care must be taken not to damage the re-adhesive surface of the body side panel. If damaged, repair should be made by urethane paint to prevent rust.
2. Cut off the sealant leaving just a thin layer.
2. APPLICATION OF ADHESIVE SEALANT TO THE BODY
a. Clean the body side sealant with alcohol or similar cleaning solvent.
NOTE: After cleaning, care must be taken not to let water or oil contaminate the surface.
b. Press resin fastener against the body.
NOTE: Press the fastener evenly so it will not rise from the body. Pay special attention to the corners.
c. For glass positioning, first install glass to the body correctly, then put tape between the body and glass as matching marks and finally cut the tape between the body and glass for repositioning.
d. Apply primer to the paint surface of the body side if necessary.
NOTE:
1. Clean the area with alcohol or similar solvent before applying the primer.
2. Apply the primer evenly using a clean brush. Make certain there are no thin or scratchy areas.
3. Allow primer to dry for 5 minutes after application.
4. Primer must be reapplied if glass cannot be Installed within 6 hours.
5. If primer is spilled on other parts of the body, it should be wiped off with alcohol or similar solvent.
e. Attach the spacer.
NOTE: Peel off the tack paper and attach the spacer to lower part of the window.
3. APPLICATION OF ADHESIVE SEALANT TO GLASS
a. Clean the glass adhesive surface with alcohol or similar solvent.
b. On the outer side of the window, along the circumference to within 7 to 9 mm (0.28 to 0.35 in) from the edge, attach the dam rubber with double-faced adhesive tape.
c. Apply primer G (for glass) with a brush.
NOTE:
1. Before attaching the dam rubber, be careful not to touch the cleaned surface.
2. Even if the primer is not discolored, do not use the primer if particles are floating inside the container.
3. After primer application, allow it to dry for 3 minutes.
4. Care must be taken to keep dust, oil, and water away from surfaces that have been primed.
d. Load the sealant cartridge into the sealant gun, and then apply the sealant, adjacent to the outer side of the dam rubber on the glass surface or body side.
NOTE:
1. Apply a larger quantity of sealant at the corners. Care must be taken not to cut the sealant when installing the glass.
2. Cut the nozzle tip of the sealant cartridge so that the diameter of the sealant will be approximately 10 mm (0.39 in).
e. Secure the glass with the glass holders (Special Tool ST0880 0000), and set them on top of the spacers.
f. After setting the glass On top of the spacers, firmly and evenly press the glass against the body for tight adhesion.
NOTE:
1. The suction cups of the glass holder must be firmly fixed to the glass.
2. Always use 2 or more people for the installation operation.
3. Do not exert continuous excessive force to the installed glass.
4. After Installing the glass, the doors should be closed until the sealant hardens. If they are opened, close gently. Do not drive the car until the sealant hardens, otherwise air will enter into the sealant, creating holes and causing leaks.
For sealant hardening time, refer to the sealant instruction manual.
4. INSPECTION FOR WATER LEAKAGE
1. PERFORM A WATER LEAKAGE TEST
- Pour water on the vehicle, and check the passenger compartment and trunk for water leakage after the hardening time has elapsed.
- Use water at a rate of 20 liters (5-1/4 US gal, 4-3/8 Imp gal) a minute. The water pressure must be at such a level that when sprayed from the waist, water falls to a place 35 - 40 cm (13.8 - 15.7 in) away. [The hose should be an ordinary garden hose of about 15 mm (0.59 in) in diameter.]
- The hose should be used as it is, or press the end of it lightly according to the condition of the panel joint. Water should be sprayed for more than 10 minutes from a distance of 3 - 30 cm (1.1 8-11.81 in).
- The water leakage inspection should be made from the lower to the upper body.
- Note: The water leakage inspection is to find out if any water leaks into the vehicle.
- For water leakage around the front and rear windows, an air checking method is available, as shown in the figure.
2. SEAL ANY WATER LEAKS
Leakage can be repaired without removing and reinstalling glass
It water is leaking between caulking material and body or between glass and caulking material, determine the extent of the leakage by applying water while pushing glass outward.
To stop the leakage, apply primer and then sealant to the leakage point.