Windshield: Service and Repair
REMOVAL1. REMOVE FRONT DOOR SCUFF PLATES
2. REMOVE COWL SIDE BOARDS
3. REMOVE FRONT DOOR OPENING TRIM COVERS
4. REMOVE FRONT PILLAR GARNISH
a. Using a screwdriver, remove the front pillar garnish.
HINT: Tape the screwdriver tip before use.
b. w/ Tweeter speaker:
Disconnect the connector.
c. Employ the same manner described above to the other side.
5. REMOVE SUN VISORS AND HOLDERS
6. REMOVE ASSIST GRIP
7. w/ Sliding roof:
REMOVE SLIDING ROOF OPENING TRIM MOULDING
8. REMOVE ROOF DRIP SIDE CHANNELS
9. REMOVE ROOF CONSOLE BOX
a. XLE, LE Grade:
Using a screwdriver, remove the 2 lenses.
HINT: Tape the screwdriver tip before use.
b. CE Grade:
Using a screwdriver, remove the lens.
HINT: Tape the screwdriver tip before use.
c. Remove the 3 screws and roof console box,then disconnect the connector.
10. REMOVE GLASSES BOX
Remove the 2 screws and glasses box.
11. REMOVE FRONT SIDE OF ROOF HEADLINING
12. REMOVE WIPER ARMS
13. REMOVE HOOD TO COWL TOP SEAL
14. REMOVE COWL TOP VENTILATOR LOUVERS
a. Remove the clip and RH cowl top ventilator louver,then disconnect the washer hose.
b. Remove the clip and LH cowl top ventilator louver,then disconnect the washer hose.
15. REMOVE OUTSIDE MOULDING
a. Attach the rivet cutter to the drill,
b. Gently and vertically put the drill to the rivet, and cut the rivet flanges.
NOTE: Prizing the hole with a drill can lead to damage to the rivet hole or breaking the rivet cutter. Take care as the cut rivet is hot.
c. Even if flange is taken off, continue drilling and push out remaining fragments with the drill.
d. Remove the outside moulding.
e. Employ the same manner described above to the other side.
16. REMOVE UPPER OUTSIDE MOULDING
Using a knife, cut off the moulding as shown.
NOTE: Do not damage the body with the knife.
17. REMOVE WINDSHIELD GLASS
a. Push piano wire through between the body and glass from the interior.
b. Tie both wire ends to wooden block or a similar object.
HINT: Apply adhesive tape to the outer surface to keep the surface from being scratched.
NOTE: When separating the glass, take care not to damage the paint and interior and exterior ornaments. To prevent scratching the safety pad when removing the windshield, place a plastic sheet between the piano wire and safety pad.
c. Cut the adhesive by pulling the piano wire around it.
d. Remove the glass.
NOTE: Leave as much of the adhesive on the body as possible when cutting off the glass.
INSTALLATION
1. CLEAN AND SHAPE CONTACT SURFACE OF BODY
a. Using a knife, cut away any rough areas on the body.
HINT: Leave as much of the adhesive on the body as possible.
b. Clean the cutting surface of the adhesive with a piece of shop rag saturated in cleaner.
HINT: Even if all the adhesive has been removed, clean the body.
2. CLEAN REMOVED GLASS
a. Using a scraper, remove the adhesive sticking to the glass.
b. Clean the glass with cleaner.
NOTE: Do not touch the glass surface after cleaning it.
3. REPLACE STOPPERS
a. Remove the damaged stoppers.
b. Cut off the old adhesive around the stopper installation area.
NOTE: Be careful not to damage the glass.
c. Clean the installation area.
d. Install new stoppers onto the glass.
A: 13.6 mm (0.98 in.)
4. REPLACE DAM
a. Remove the damaged dam.
b. Clean the installation area.
c. Install a new dam with adhesive tape as shown in the illustration.
NOTE: Do not touch the glass surface after cleaning it.
5. INSTALL N0.2 DAM
a. Remove the damaged dam.
b. Clean the installation area.
c. Install the dam with adhesive tape as shown in the illustration.
NOTE: Do not touch the glass surface after cleaning it.
A: 22.0 mm (0.87 in.)
B: 3.0 ± 3.0 mm (0.12 ± 0.12 in.)
6. POSITION GLASS
a. Place glass in the correct position.
b. Check that all contacting parts of the glass rim are perfectly even and do not make contact with the fasteners.
c. Place reference marks between the glass and body.
d. Remove the glass.
7. CLEAN CONTACT SURFACE OF GLASS
Using a cleaner, clean the contact surface which is black-colored area around the entire glass rim.
NOTE: Do not touch the glass face after cleaning it.
8. COAT CONTACT SURFACE OF BODY WITH PRIMER "M"
Using a brush, coat Primer M to the exposed part of body on the vehicle side.
NOTE:
- Let the primer coating dry for 3 minutes or more.
- Do not coat primer M to the adhesive.
- Do not keep any of the opened primer M for later use.
9. COAT CONTACT SURFACE OF GLASS WITH PRIMER "G"
a. Using a brush or a sponge, coat the edge of the glass and the contact surface with primer G.
b. Before the primer dries, wipe it off with a clean shop rag.
NOTE:
- Let the primer coating dry for 3 minutes or more.
- Do not keep any of the opened primer G for later use.
10. APPLY ADHESIVE
a. Cut off the tip of the cartridge nozzle.
Part No. 08850-00801 or equivalent
HINT: After cutting off the tip, use all adhesive within the time described in the table.
b. Load the cartridge into the sealer gun.
c. Coat the glass with adhesive as shown.
A: 12.0 mm (0.472 in.)
B: 8.0 mm (0.315 in.)
11. INSTALL GLASS
HINT: Check that the dam is attached to the body panel as shown in the illustration.
a. Position the glass so that the reference marks are lined up, and press in gently along the rim.
b. Using a spatula, apply adhesive on the glass rim.
c. Use a scraper to remove any excessive or protruding adhesive.
d. Hold the glass in place securely with a protective tape or equivalent until the adhesive hardens.
NOTE: Take care not to drive the vehicle during the time described in the table.
12. INSPECT FOR LEAK AND REPAIR
a. Conduct a leak test after the hardening time has elapsed.
b. Seal any leak with sealant.
Part No. 08833-00030 or equivalent
13. APPLY ADHESIVE TO MOULDING INSTALLATION AREA
Apply adhesive to the moulding installation area between the glass and the body.
Part No. 08833-00030 or equivalent
14. INSTALL UPPER OUTSIDE MOULDING
Place the moulding onto the body and tap it by hand.
15. INSTALL OUTSIDE MOULDING
a. Using an air riveter or hand riveter, install the 3 rivets and outside moulding.
b. Employ the same manner described above to the other side.
NOTE: At the time of reassembly, please refer to the following items.
- Do not prize a riveter, as riveter is damaged, it is not tightened and the mandrel is bent.
- Do not tilt the riveter and disconnect the rivet from the material while handling a riveter, as the materials are not tightened firmly.
- Install the rivet while attaching materials, as they are not tightened firmly.
16. INSTALL COWL TOP VENTILATOR LOUVERS
17. INSTALL HOOD TO COWL TOP SEAL
18. INSTALL WIPER ARMS
a. Operate the wipers once and turn the wiper switch OFF.
b. Install the wiper arms and tighten nuts by hand.
c. Adjust the installation position of the wiper arms to the positions shown in the illustration.
A: Approx. 25.0 mm (0.98 in.)
B: Approx. 32.0 mm (1.26 in.)
d. Torque the nuts.
Torque: 20 N.m (205 kgf.cm, 15 ft.lbf)
e. Install the wiper arm head caps.
19. INSTALL FRONT SIDE OF ROOF HEADLINING
20. INSTALL GLASSES BOX
21. INSTALL ROOF CONSOLE BOX
22. INSTALL ROOF DRIP SIDE CHANNELS
23. w/ Sliding roof:
INSTALL SLIDING ROOF OPENING TRIM MOULDING
24. INSTALL ASSIST GRIP
25. INSTALL SUN VISORS AND HOLDERS
26. INSTALL FRONT PILLAR GARNISHES
27. INSTALL FRONT DOOR OPENING TRIM COVERS
28. INSTALL COWL SIDE BOARDS
29. INSTALL FRONT DOOR SCUFF PLATES