Windshield: Service and Repair

Windshield Removal and Installation

Windshield Construction

Removal

1) Clean both inside and outside of glass and around it.
2) Remove wiper arms and cowl top garnish.
3) Remove windshield side garnish.
4) Using tape, cover body surface around glass to prevent any damage.
5) Remove rear view mirror, sun visor and front pillar trims (right & left).
6) If necessary, remove instrument panel. Refer to Service and Repair Instrument Panel Removal and Installation.
7) If necessary, remove head lining. Refer to Service and Repair Head Lining Removal and Installation.
8) Remove (or cut) windshield molding.
9) Drill hole with eyeleteer (1) through adhesive and let piano string through it.





10) Cut adhesive all around windshield (1) with piano string (2). When using tool, windshield knife (3), to cut adhesive, be careful not to cause damage to windshield. Use wire to cut adhesive along lower part of windshield.

NOTE:
If piano string contacts the vehicle body or the instrument panel when cutting the windshield adhesive with it, the vehicle body and/or instrument panel may be damaged.

Use piano string by keeping it as close to windshield glass as possible.





11) Using knife (1), smoothen adhesive (2) remaining on body side (3) so that it is 1 - 2 mm (0.039 - 0.078 in.) thick all around.

NOTE:
Before using knife (1), clean it with alcohol or the like to remove oil from it.





12) When reusing windshield, remove the adhesive (1) from it, using care not to damage primer coated surface (2).






Installation

1) Using cleaning solvent, clean windshield edge where windshield glass is to be adhered. (Let it dry for more than 10 minutes.)
2) To determine installing position of glass (1) to body (2), position glass against body so that clearance between upper end of glass (1) and body (2) is approximately 5.5 mm (0.217 in.) and clearances between each side end (right & left) of glass (1) and body (2) are even. Then mark mating marks on glass (1) and body (2) as shown. Upper clearance can be adjusted by moving glass stoppers position.

Windshield clearance
"a": approx. 5.5 mm (0.217 in.)





3) Clean contact surfaces of old adhesive (4), paint or bare metal thoroughly.

If surfaces of paint or bare metal come out, apply primer (2) for body with caution not to apply primer (2) to surface of adhesive remaining on body.

NOTE:
- Be sure to refer to primer maker's instruction for proper handling and drying time.
- Do not touch body and old adhesive surfaces where glass is to be adhered.









4) Install new molding to glass.
5) Clean glass surface to be adhered to body with clean cloth. If cleaning solvent is used, let it dry for 10 minutes or more.

Cleaning Area for windshield (distance from the edge of glass or molding)
30 - 50 mm (1.18 - 1.97 in.)

6) Install new fastener (1) to windshield (2).





7) Using new brush, apply sufficient amount of primer onto glass along glass edge.

NOTE:
- Be sure to refer to maker's instruction for proper handling and drying time.
- Do not apply primer on outside of ceramic coated surface.
- Do not touch primer coated surface.

Width applied primer for windshield
"a": 15 mm (0.59 in.)
"b": 20 mm (0.79 in.)









8) Apply primer for molding along molding surface all around.
9) Apply adhesive (1) referring to figure.

NOTE:
- Perform steps 8) to 9) within 10 min. to ensure sufficient adhesion.
- Be careful not to damage primer.

Adhesive amount specifications and position for windshield
Width "a": Approx. 7 mm (0.27 in.)
Height "b": Approx. 15 mm (0.59 in.)
Position "c": Approx. 4 mm (0.15 in.)
Position "d": Approx. 31 mm (1.22 in.) for bottom section









10) Holding rubber sucker grips (1), place glass onto body by aligning mating marks in step 2) and press it quickly after adhesive is applied.





11) Check for water leakage by pouring water over windshield through hose. If leakage is found, dry windshield and fill leaky point with adhesive. If water still leaks even after that, remove glass and start installation procedure all over again.

NOTE:
Doing water leakage check using water at too high a pressure may cause the adhesive to get detached.

Use water flowing from a hose without pressurizing it to check for water leakage.





NOTE:
Adhesive requires a minimum hardening time, which varies with the type of the adhesive used. If proper precautions are not taken during this hardening time, problems such as poor sealing, loosening, and detachment of the windshield glass can occur.
- Avoid quickly closing a door before complete hardening of the adhesive. Closing a door quickly could cause the windshield glass to become loose or even come off. If a door must be closed before the adhesive hardens completely, open all side windows first and then gently close the door.
- If molding is not securely in place, hold it down with tape until the adhesive completely hardens.
- Be sure to check the hardening time of the adhesive used and observe the precautions to take during the hardening time.
- Refrain from driving until the adhesive completely hardens.
- Do not blow compressed air directly at adhesive applied part when drying.
- Do not use infrared light or like for drying.