Windshield: Service and Repair
REMOVAL1. REMOVE THESE PARTS:
a. Front door opening trims
b. Front pillar garnishes
c. Sun visors
d. Double visors
e. Holder
f. Overhead console box
g. Inner rear view mirror
2. REMOVE WIPER ARM AND COWL TIP VENTILATOR LOUVER
3. REMOVE OUTSIDE MOULDING
a. Using a screwdriver, remove the outside No. 2 moulding.
HINT: Tape the screwdriver tip before use.
b. Using a drill of less than Dia 4 mm (0.16 in.)
c. 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 drill.
- Take care as the cut rivet is hot.
d. Even if flange is taken off, continue drilling and push out remaining fragments with the drill.
e. Using a heat light, heat the moulding to 20 - 30 degrees C (68 - 86 degrees F).
NOTE: Do not heat the moulding excessively.
f. Tie both piano wire ends to wooden blocks or a similar object.
g. Cut the adhesive tape by pulling the piano wire as shown.
NOTE:
- If reusing the moulding, take care not to damage the moulding.
- Do not damage the body.
HINT: Apply protective tape to the outer surface to keep the surface from being scratched.
h. Remove the moulding.
4. REMOVE OUTSIDE 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 wooden blocks or similar object.
HINT: Apply protective 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 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.
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 STOPPER
a. Remove the damaged stopper.
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 a new stopper onto the glass.
A: 9 mm (0.35 in.)
B: 25 mm (0.98 in.)
4. INSTALL DAM
Install new dams with adhesive tape as shown in the illustration.
NOTE: Do not touch the glass surface after cleaning it.
A: 7 mm (0.28 in.)
B: 20 mm (0.79 in.)
5. POSITION GLASS
a. Place glass in the correct position.
b. Check that all contacting parts of the glass rim are perfectly even.
c. Place reference marks between the glass and body.
d. Remove the glass.
6. 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.
7. COAT CONTACT SURFACE OF BODY WITH PRIMER "M"
Using a brush, coat Primer M to 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.
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. When the primer is coated wrongly to the area other than the specified, wipe it off with a clean shop rag before the primer dries.
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.
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.)
10. 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. Using a scraper 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.
11. 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.
12. 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.
13. INSTALL UPPER OUTSIDE MOULDING
Place a new moulding onto the body and tap it by hand.
14. INSTALL OUTSIDE MOULDING
Using an air riveter with nose piece No. 4, install 4 new rivets and outside moulding.
HINT: Before using the air riveter with nose piece No. 4, cut 5 mm (0.20 in.) at the edge of nose piece No. 4.
NOTE:
- At the time of assembly, please refer to the following items.
- Prizing a riveter leads to damage to the riveter; loose tightening and bending the mandrel.
- Loose tightening may result from either tilting the riveter while handling or the riveter not connecting to the material.
- Loose tightening also occurs when a rivet is applied between materials without touching.
15. INSTALL WIPER ARM AND COWL TOP VENTILATOR LOUVER
16. INSTALL THESE PARTS:
a. Inner rear view mirror
b. Overhead console box
c. Holder
d. Double visors
e. Sun visors
f. Front pillar garnishes
g. Front door opening trims