Windshield: Service and Repair
REMOVAL1. REMOVE THESE PARTS:
a. Inner rear view mirror
b. Sun visors and holders
c. Map light assembly
d. Front pillar garnishes
e. Hood
f. Wiper arms
g. Cowl louvers
h. Weatherstrips
2. REMOVE WEATHERSTRIP
Remove the weatherstrip by pulling.
HINT: Remove only the front half of weatherstrip.
3. REMOVE WINDSHIELD OUTSIDE MOULDING
a. Using a drill of less than dia. 5.0 mm (0.20 in.), drill out the rivet heads and remove the moulding.
b. Using a vacuum cleaner, remove the drill rivet and their dust from the inside of the door.
CAUTION: The cut rivet and rivet cutter will be not, avoid touching them.
NOTE: Do not jiggle the rivet cutter while cutting.You may enlarge the rivet hole or damage the rivet cutter.
HINT: Do not drill the body.
Sealant may cause the moulding to stick to the glass. If necessary, separate from the glass using a knife.
4. REMOVE WINDSHIELD UPPER MOULDING
Using a knife, cut off the moulding as shown.
NOTE: Do not damage the body with the knife.
5. REMOVE WINDSHIELD GLASS
a. Push piano wire through between the body and glass from the interior.
b. Tie both wire ends to a wooden block or a similar object.
HINT: Apply adhesive tape to the outer surface to prevent scratching.
NOTE: When separating the glass, be careful 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 removing the glass.
6. REMOVE RETAINERS
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. REPLACE STOPPER
a. Remove the damaged stopper.
b. Cut off the old adhesive around the stopper installation area.
NOTE: Be careful not to damage the body.
c. Clean the installation area.
d. Install a new stopper onto the body.
3. 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 after cleaning it.
4. 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.
5. CLEAN CONTACT SURFACE OF GLASS
Using a cleaner, clean the contact surface black-colored area around the entire glass rim.
NOTE: Do not touch the glass face after cleaning it.
6. INSTALL DAM
Install the dam with double-stick tape as shown in the illustration.
NOTE: Do not touch the glass face after cleaning it.
A: 7 mm (0.276 in.)
7. COAT CONTACT SURFACE OF BODY WITH PRIMER "M"
Using a brush, coat the contact surface on the body with Primer M.
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.
8. 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.
9. APPLY ADHESIVE
a. Cut off the tip of the cartridge nozzle. Fill the cartridge with adhesive.
Part No. 08850 - 00801 or equivalent
HINT: After cutting off the tip, use all adhesive within the time described in the chart.
b. Load the cartridge into the sealer gun.
c. Coat the glass with adhesive as shown.
10. INSTALL GLASS
HINT: Confirm that the dam is attached 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 excess or protruding adhesive.
NOTE: Take care not to drive the vehicle during the time described in the chart.
d. Hold the windshield glass in place securely with a protective tape or equivalent until the adhesive hardened.
11. INSPECT FOR LEAKS AND REPAIR
a. Do a leak test after the hardening time has elapsed.
b. Seal any leak with sealant.
Part No. 08833 - 00030 or equivalent
12. APPLY ADHESIVE AT MOULDING INSTALLATION AREA
Part No. 08833 - 00030 or equivalent
13. INSTALL WINDSHIELD UPPER MOULDING
Place the moulding onto the body and tap it in by hand.
14. INSTALL WINDSHIELD OUTSIDE MOULDING
a. Install the pawl of the outside moulding to the upper moulding to set the moulding to the body.
b. Using an air riveter with nose piece, install the new 3 rivets and outside moulding.
CAUTION: To avoid personal injury and short of the wiring when installing dia. 5.0 mm (0.20 in.) rivets keep your hands out of the 20 mm (0.79 in.) radius that the caulked Dia 5.0 mm (0.20 in.) rivet will cover.
HINT: Install the rivet firmly pressed at a right angle (9 degrees) against the installation hole.
15. INSTALL THESE PARTS:
a. Cowl louvers
b. Weatherstrips
c. Wiper arms
Torque: 24 N.m (245 kgf.cm, 18 ft.lbf)
d. Front pillar garnishes
e. Map light assembly
f. Sun visors and holders
g. Inner rear view mirror