Windshield: Service and Repair

Windshield Glass

Fixed Glass:

REMOVAL

1. WHEN USING WINDSHIELD GLASS KNIFE

CAUTION: Apply protective tape, etc, and be careful that the inner and outer components of the vehicle are not damaged.

1. Disconnect the ground cable from battery. (Models with wiper deicer)
2. Remove the front pillar upper trim.
3. Disconnect the wiper deicer connector. (Models with wiper deicer)
4. Remove the cowl panel.
5. Remove the glass molding.
6. Tape the body side of the circumference of windshield glass for protection.
7. Apply sufficient amount of soapy water to the adhesive part.
8. Make a slit using a cutter knife to make it easier to insert the windshield glass knife.
9. Insert the windshield glass knife into adhesive part.
10. While holding the knife edge and windshield glass edge at a right angle, move the windshield glass knife in parallel to the windshield glass edge along the surface and edge of windshield glass to cut the adhesive part.

NOTE:
- Do not twist the windshield glass knife.
- Cutting of adhesive part shall be started with wider gap between windshield glass and body.







- The locating pins are bonded to the corners of glass. Use piano wire to disconnect the pins.







2. WHEN USING PIANO WIRE

CAUTION:
- Do not tightly pull the piano wire against the windshield glass edge.
- Apply protective tape, etc., and be careful not to damage interior and exterior parts.
- Do not cross piano wires. Otherwise they may be cut.

1. Disconnect the ground cable from battery. (Models with wiper deicer)
2. Remove the front pillar upper trim.
3. Disconnect the wiper deicer connector. (Models with wiper deicer)
4. Remove the cowl panel.
5. Remove the glass molding.
6. Tape the body side of the circumference of windshield glass for protection.
7. Using a drill or razor blade, make a hole in the adhesive part.
8. Pass the piano wire through the hole, and attach both the wire ends securely to pieces of wood.







9. Pull the wire ends alternately to cut off the adhesive part.

INSTALLATION

1. Cut the cartridge nozzle tip as shown in the figure, and set the adhesive in the sealant gun.







2. Clean the external circumference of windshield glass with alcohol or white gasoline
3. Remove the adhesive layer on the body using cutter knife to obtain smooth face of 2 mm (0.08 in) thick.

CAUTION: Be careful not to damage the body and paint surface.







4. Clean the body with alcohol or white gasoline to eliminate cutting powder, dust and dirt completely from body.
5. Install the dam rubber.







6. Attach the molding to the glass.







1. Align the molding (A) to the upper ends of the windshield glass (C).
2. Attach the molding from the upper corners towards the center.
3. Attach the molding from the upper corners downward.
4. Firmly apply the double sided tape (B) of the molding evenly to the end face of the glass.

7. Apply the seal to the molding.







NOTE: Apply so that the sticker does not overlap out to the adhesive side (6).

8. Using a sponge, apply primer to the glass side and body side adhesive surfaces.

Glass primer:
Dow Automotive
- ESSEX U-401, U-402 or equivalent

Painted surface primer:
Dow Automotive
- ESSEX U-413 or equivalent

NOTE:
- Primer once attached to the painted surface of the body and internal trim is hard to wipe off. Mask the circumference of such area.
- Let primer dry for about ten minutes before installing the glass.
- Do not touch the surface coated with primer.







9. Apply adhesive to the glass end surface as shown in the figure.

Adhesive:
Dow Automotive
- ESSEX U-400HV or equivalent
















10. Using suction rubber cups, fit the locator pins into the body side, and attach the windshield glass.







11. Lightly press the windshield glass for tight fit.
12. Make flush the adhesive surface jutted out using spatula.
13. After completion of all work, allow the vehicle to stand for about 24 hours.

NOTE:
- When door is opened/closed after glass is bonded, always lower the door glass first, and then open/close it carefully.
- Move the vehicle slowly.
- For minimum drying time and vehicle standing time before driving after bonding, follow instructions or instruction manual from the adhesive manufacturer.

14. After curing of adhesive, pour the 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.

15. Install the cowl panel.
16. Connect the wiper deicer connector. (Models with wiper deicer)
17. Install the front pillar upper trim.