Windshield: Service and Repair

Windshield:

REMOVAL SERVICE POINT

<> WINDSHIELD REMOVAL

1. To protect the body (paint surface), apply cloth tape to all body areas around the installed windshield.
2. Make mating marks on the windshield and body.







3. Using a sharp-point drill, make a hole in the windshield adhesive.
4. Pass the piano wire from the inside of the vehicle through the hole.

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

5. Pull the piano wire alternately from the inside and outside along the windshield to cut the adhesive.






6. Use special tool MB990480 to remove the windshield.

CAUTION: Be careful not to remove more adhesive than is necessary.
Be careful also not to damage the paintwork on the body surface with the knife. If the paintwork is damaged, repair the damaged area with repair paint or antirust agent.

7. Use a knife to cut away the remaining adhesive so that the thickness is within 2 mm (0.08 inch) around the entire circumference of the body flange.

8. Finish the flange surfaces so that they are smooth.

CAUTION: Allow the cleaned area to dry for at least three minutes. Do not touch any surface that has been cleaned.







9. When reusing the windshield, remove the adhesive still adhering to the windshield, and clean with 3M(TM) AAD Part number 8906 or equivalent.
10. Clean the body side in the same way.




INSTALLATION SERVICE POINT

>>A<< DUAL LOCK FASTENER/WINDSHIELD INSTALLATION

1. When replacing the windshield, temporarily set the windshield against the body, and place a mating mark on the windshield and body.
2. Use 3M(TM) AAD Part number 8906 or equivalent to degrease the inside and outside of the windshield and the body flanges.

CAUTION: The primer strengthens the adhesive, so be sure to apply it evenly around the entire circumference. However, a too thick application will weaken the adhesive.
Do not touch the coated surface.

3. Soak a sponge in the primer, and apply evenly to the windshield and the body in the specified places.
4. Allow the windshield to dry for at least three minutes after applying primer.







5. Install the dual lock fasteners to the windshield in the position shown in the illustration.
6. Install the dual lock fasteners to the body flange in the positions that are corresponding to those on the windshield.







7. Fill a sealant gun with adhesive. Then apply the adhesive evenly around the windshield within 30 minutes after applying the primer.

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

8. Align the mating marks on the windshield and the body, and lightly press the windshield evenly so that it adheres completely.
9. Use a spatula or similar tool to remove any excessive adhesive. Clean the surface with 3M(TM) AAD Part number 8906 or equivalent. Avoid moving the vehicle until the adhesive sets.

CAUTION: Do not move the vehicle unless absolutely necessary.
When testing for water leakage, do not pinch the end of the hose to spray the water.

10. Wait 30 minutes or more, and then test for water leakage.