Windshield: Service and Repair

Windshield Glass

REMOVAL

1. USING WINDSHIELD KNIFE
1. Remove the cowl panel.
2. Remove the glass molding.
3. Tape the body side of the circumference of windshield glass for protection.
4. Apply sufficient amount of soapy water to the adhesive layer.
5. Insert the windshield knife into the adhesive layer.







6. While holding the knife edge and windshield glass edge at a right angle, move the windshield knife in parallel to the windshield glass edge along face and edge of windshield glass to cut the adhesive layer.

NOTE: Because the matching pins are bonded to the corners of glass, use piano wire to cut the pin.

2. USING PIANO WIRE
1. Remove the cowl panel.
2. Remove the roof molding and upper front molding.
3. Tape the body side of the circumference of windshield glass for protection.
4. Make a hole in the adhesive layer using a drill or knife.




5. Pass the piano wire through the hole, and attach securely both the wire ends to pieces of wood.
6. Pull the wire ends alternately to cut off the adhesive layer.

INSTALLATION

1. Clean the external circumference of windshield glass with alcohol or white gasoline.




2. Remove the adhesive layer on the body using cutter knife to obtain smooth face 2 mm (0.08 in) thick.
3. Clean the body with alcohol or white gasoline to remove thoroughly chips, dusts, and dirts from body face.




4. Apply the dam rubber to back of glass.




5. Remove the backing of double-faced adhesive tape, and then align the molding mark (B) to notch (A). Attach the molding around the edge of glass, and then press it evenly to fit.
6. Apply primer to the adhesive layer of glass using sponge.




7. Apply primer to the adhesive layer of body. Primer once attached to the painted surface of the body and internal trim is hard to wipe off. Mask the circumference of such areas. Let the primer dry for about ten minutes before installing the glass.




8. Cut off the cartridge nozzle tip and set it in sealant gun as shown.
9. Apply adhesive to the glass end surface as shown.




10. Fit the matching pins using suction rubber cup to install the windshield glass.
11. Lightly press the windshield glass for tight fit.
12. After completion of all work, allow the vehicle to stand for about 24 hours.

NOTE: For minimum drying time and time the vehicle must be left standing before driving after bonding, follow instructions or instruction manual from the adhesive manufacturer.

13. After curing of adhesive, pour water on external surface of vehicle to check that there are no water leaks.

NOTE: When a vehicle is returned to the user, tell him or her that the vehicle should not be subjected to heavy impact for at least three days.

14. Install the cowl panel.