Windshield: Service and Repair
REMOVAL1. REMOVE FRONT DOOR OPENING TRIMS
2. REMOVE FRONT PILLAR GARNISH
a. Driver's side:
Using a screwdriver, remove the 2 assist grip plugs, then remove the 2 screws and assist grip.
HINT: Tape the screwdriver tip before use.
b. Passenger's side:
Using a screwdriver, remove the 4 assist grip plugs, then remove the 4 screws and 2 assist grips.
HINT: Tape the screwdriver tip before use.
c. Using a screwdriver, remove the front pillar garnish.
HINT: Tape the screwdriver tip before use.
d. Employ the same manner described above to the other side.
3. REMOVE SUN VISORS
4. REMOVE DOUBLE VISORS
5. REMOVE HOLDERS
6. w/ Sliding roof:
REMOVE OVERHEAD CONSOLE BOX
a. Remove the 2 bolts.
b. Using a screwdriver, remove the overhead console box, then disconnect the connector.
HINT: Tape the screwdriver tip before use.
7. w/o Sliding roof:
REMOVE OVERHEAD CONSOLE BOX
a. Remove the bolt.
b. Using a screwdriver, remove the map light assembly, then disconnect the connector.
HINT: Tape the screwdriver tip before use.
c. Using a screwdriver, remove the 2 lenses.
HINT: Tape the screwdriver tip before use.
d. Remove the 4 bolts.
e. Using a screwdriver, remove the overhead console box, then disconnect the connector.
HINT: Tape the screwdriver tip before use.
8. REMOVE INNER REAR VIEW MIRROR
9. REMOVE WIPER ARMS
a. Remove the 2 caps and 2 nuts.
b. Remove the 2 wiper arms.
10. REMOVE HOOD TO COWL TOP SEAL
11. REMOVE LH AND RH COWL TOP VENTILATOR LOUVERS
a. Remove the RH cowl top ventilator louver.
b. Remove the LH cowl top ventilator louver.
12. 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 then 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 cafe 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 similar objects.
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,
i. Employ the same manner described above to the other side.
13. REMOVE OUTSIDE UPPER MOULDING
Using a knife, cut off the moulding as shown in the illustration.
NOTE: Do not damage the body with the knife.
14. 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 objects.
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. Remove the damaged stoppers and dams.
b. Using a scraper, remove the adhesive sticking to the glass.
c. Clean the glass with cleaner.
NOTE: Do not touch the glass surface after cleaning it.
3. INSTALL NEW STOPPERS
Install new stoppers onto the glass.
A: 9 mm (0.35 in.)
B: 25 mm (0.98 in.)
4. INSTALL NEW DAMS
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 and do not make contact with the fasteners.
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 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.
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
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.
HINT: Confirm that the dam is attached to the body panel, as shown in the illustration.
d. Hold the windshield glass in place securely with a protective tape or equivalent until the adhesive hardens.
e. 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
a. 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:
- 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.
b. Employ the same manner described above to the other side.
15. INSTALL COWL TOP VENTILATOR LOUVERS
a. Install the LH cowl top ventilator louver.
b. Install the RH cowl top ventilator louver.
16. INSTALL HOOD TO COWL TOP SEAL
17. 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. 40 mm (1.57 in.)
B: Approx. 26 mm (1.02 in.)
d. Torque the nuts.
Torque: 20 N.m (204 kgf.cm, 15 ft.lbf)
e. Install the wiper arm caps.
18. INSTALL INNER REAR VIEW MIRROR
19. w/o Sliding roof:
INSTALL OVERHEAD CONSOLE BOX
a. Connect the connector.
b. Install the overhead console box with 4 bolts.
c. Install the 2 lenses.
d. Connect the connector, then install the map light assembly with the bolt.
20. w/ Sliding roof:
INSTALL OVERHEAD CONSOLE BOX
Connect the connector, then install the overhead console box with the 2 bolts.
21. INSTALL HOLDERS
22. INSTALL DOUBLE VISORS
23. INSTALL SUN VISORS
24. INSTALL FRONT PILLAR GARNISH
a. Install the front pillar garnish.
b. Employ the same manner described above to the other side.
c. Driver's side:
Install the assist grip with the 2 screws, then install the 2 assist grip plugs.
d. Passenger's side:
Install the 2 assist grips with the 4 screws, then install the 4 assist grip plugs.
25. INSTALL FRONT DOOR OPENING TRIMS