Installation
Windshield GlassINSTALLATION
1. Cleaning of windshield glass
1. When the windshield glass is reused.
a. Using a scraper or similar tool, remove the adhesive and/or double-sided tape remaining on the windshield glass.
CAUTION: Do not damage the windshield glass.
2. Using the white gasoline, clean the rim of the windshield glass.
CAUTION: New windshield glass also needs to be cleaned.
2. Installation of windshield glass stopper No. 1
1. Apply primer to the mounting surface of the windshield glass stopper No. 1 for attachment to the glass.
Primer: SUNSTAR, #435-70
2. Apply primer to the mounting surface on the windshield glass for attachment of the windshield glass stopper No. 1.
Primer: SUNSTAR, #435-40
CAUTION: Primer for the windshield glass stopper needs to be dried for 10 minutes or more after application.
3. After the primer has been dried, apply adhesive to the mounting surface of the windshield glass stopper No. 1.
Adhesive: SUNSTAR #560
4. Align the windshield glass stopper No. 1 with the mounting hole and install it.
3. Installation of windshield glass stopper No. 2
1. Install it in the same manner as the RH side.
4. Installation of windshield outside molding
1. Apply primer to the installation area for the windshield outside molding on the windshield glass.
Primer: SUNSTAR #GP402
CAUTION: Apply the primer to the ceramic part only.
2. After the primer has been dried, align the windshield outside molding with both side of the windshield glass.
3. Using a roller, crimp the windshield outside molding in the direction specified by the arrows in the figure.
Standard value: 50 N/100 mm {5.1 kgf/3.94 in} {11.2 lbf/3.94 in}
CAUTION: Be careful to attach the windshield outside molding firmly to make no loose or undulating part.
4. Using a roller, crimp the windshield outside molding in the direction specified by the arrows in the figure.
Standard value: 50 N/100 mm {5.1 kgf/3.94 in} {11.2 lbf/3.94 in}
CAUTION: Be careful to attach the windshield outside molding firmly to make no loose or undulating part.
5. INSTALL UPPER WINDSHIELD GLASS SEAL
1. Remove the release paper from the upper windshield glass seal.
NOTE: After removing the release paper, keep the exposed adhesive free from foreign matter.
2. Install the upper windshield glass seal to the windshield outside molding, as shown in the illustration.
6. INSTALL WINDOW GLASS ADHESIVE DAM
1. Install the new window glass adhesive dam onto the windshield glass, as shown in the illustration.
NOTE: Use the same procedure for both the RH and LH sides.
7. INSTALL LOWER WINDSHIELD GLASS SEAL
1. Install the new lower windshield glass seal onto the windshield glass, as shown in the illustration.
NOTE: Use the same procedure for both the RH and LH sides.
8. Installation of windshield glass
1. Cleaning of mounting surface of the body
a. Remove the adhesive layer on the body using cutter knife or similar tool to obtain smooth surface of 2 mm {0.08 in} thick.
CAUTION:
- Do not damage the body.
- Always leave a little amount of adhesive.
b. Using the white gasoline, clean mounting surface of the body.
2. Windshield glass pre-installation work
a. Attach the suction rubber onto the windshield glass.
b. Place the windshield glass on the body temporary, and set them so that windshield glass's upper end and both side have same width (consistent clearance between body and windshield glass edge).
c. Apply packing tapes or similar tapes on the windshield glass and body panel, and put alignment marks on them with a pen for reinstallation. (When new glass is used.)
CAUTION: From inside the vehicle, check that windshield locate pin RH and windshield locate pin LH are engaged on the body.
NOTE: When windshield glass will be reused, check and correct the position of the alignment marks.
d. Detach the windshield glass.
e. Apply primer on the body surface.
Primer: The Dow Automotive ESSEX U-413 or equivalent.
CAUTION: Never apply the primer too thick.
3. Apply primer onto backside of the windshield glass, where indicated in the figure.
Primer: The Dow Automotive ESSEX U-401, U402, or equivalent.
CAUTION: Never apply the primer too thick.
4. Cut the tip of the adhesive nozzle, as shown in the figure.
5. Set the adhesive into the sealant gun.
Adhesive : The Dow Automotive ESSEX U-400HV or equivalent
6. Apply a bead of adhesive as shown in below.
CAUTION: Apply adhesive after the primer dried (approx. after 10 minutes).
7. Installation of windshield glass
a. Holding the suction rubbers, position the alignment marks and install the windshield glass.
CAUTION:
- After body side primer is dried (approx. 10 minutes), attach the windshield glass.
- From inside the vehicle, check that windshield glass stopper No. 1 and windshield glass stopper No. 2 are engaged.
b. Lightly press the front side of the windshield glass to fit tightly.
NOTE: Pressing force: 98 N {10 kgf} {22.0 lbf} or more
c. Using protection tapes or similar tapes, hold the windshield glass until the adhesive cures completely.
NOTE: For minimum drying time or waiting time after the cure of adhesive, consult the instruction or manual of each adhesive supplier.
9. Leak test and repair
1. After the adhesive cure, pour water over the vehicle and make sure no water leak inside.
2. If any water leak is found, fill the three cement black after the drying.
3. Remove the applied protective tape and packing tape.
10. Installation of roof head lining ASSY
1. Install the roof head lining ASSY front side (parts).
11. Installation of cowl ventilator louver
12. Installation of front fender to cowl side seal LH
13. Installation of front fender to cowl side seal RH
14. Installation of front wiper arm & blade ASSY RH
15. Installation of front wiper arm & blade ASSY LH
16. Installation of wiper arm head cap