Windshield: Service and Repair

REMOVAL AND INSTALLATION

REMOVAL SERVICE POINTS

WINDSHIELD SIDE MOULDING (L.H.)/WINDSHIELD SIDE MOULDING (R.H.)/WINDSHIELD UPPER MOULDING REMOVAL
Use the special tool to lever out each moulding.

CAUTION: Mouldings that become warped should not be re-used.

WINDSHIELD GLASS REMOVAL

1. To protect the body (paint surface), apply cloth tape to all body areas around the installed windshield glass.
2. Use a sharp-pointed drill to make a hole in the windshield glass adhesive.
3. Pass wire from the inside of the vehicle through the hole.
4. Pull the wire alternately from the inside and outside along the windshield glass to cut the adhesive.

CAUTION: Do not let the wire touch the edge of the windshield glass.

5. Make mating marks on the windshield glass and body.
6. Use the glass holders to remove the windshield glass.

7. Use a knife to cut away the remaining adhesive so that the thickness is within 2 mm (0.080 in.) around the entire circumference of the body flange.
8. Finish the flange surfaces so that they are smooth.

CAUTION:
1. Be careful not to remove more adhesive than is necessary.
2. Be careful also not to damage the paint-work on the body surface with the knife. If the paint- work is damaged, repair the damaged area with repair paint or anti-rust agent.

9. When reusing the glass, remove the adhesive and window spacer chips still adhering to the window glass, and clean with 3M AAD Part No. 8880 or equivalent.
10. Clean the body side in the same way.

CAUTION: Let the cleaned places stand for 3 minutes or more, and carry out the next procedures after they have dried. Also, do not touch any surface that has been cleaned.

INSTALLATION SERVICE POINTS

>A< WINDOW SPACER INSTALLATION
After cleaning the window spacer adhesion surface of the windshield glass with 3M AAD Part No. 8880 or equivalent to remove all grease, etc., attach the window spacer as shown in the illustration.

>B< WINDSHIELD GLASS/WINDSHIELD LOWER MOULDING INSTALLATION

1. When replacing the glass, provisionally set the glass against the body, and put mating marks on the glass and body where they match.
2. Install the windshield lower moulding onto the windshield glass.
3. Soak a sponge in the primer, and apply evenly to the glass and the body in the places shown in the illustration.

Specified primer:
3M Super Fast Urethan Primer Part No. 8608 or equivalent

CAUTION:
1. The primer strengthens the adhesive strength, so be sure to apply it evenly around the entire circumference. Also, a too thick application will cause lowering of the adhesive strength.
2. Do not touch the coated surface.

4. After applying the primer, let it dry for 3 to 30 minutes.

5. Within 30 minutes after applying the primer, fill the sealant gun with adhesive and apply the adhesive evenly around the entire circumference of the windshield.

Specified adhesive:
3M Super Fast Urethan Auto Glass Sealant Part No. 8609 or equivalent

NOTE: Cut the nozzle tip of the sealant gun into a V shape to facilitate adhesive application.

6. Match up the mating marks on the glass and the body, and lightly press the windshield glass evenly so that it adheres completely.
7. After removing any adhesive that is sticking out or adhering to the body or glass with a spatula, etc., clean off with 3M MD Part No. 8906 or equivalent.

After completion of this operation (after installing the glass), place it somewhere where it will not be disturbed, until the adhesive sets.

CAUTION: If heat is applied with an infra-red lamp to shorten the setting time, keep the surface temperature of the adhesive below 100 °C.

8. After attaching the windshield glass to the body, let it stand for 30 minutes or more, and then test for water leakage.

CAUTION:
1. If moving the vehicle, it should be done gently.
2. When testing for water leakage, do not pinch the end of the hose to spray the water.

WINDSHIELD CLIP STUD REPAIR
If the T-studs are broken, use a drill to make holes 3 mm (0.120 in.) in diameter in the T-studs, till the holes with adhesive, and then use screws to mount the window moulding clips.

CAUTION: After installing the clips, apply anti-rust solvent to the screw heads to protect them from rust.