Windshield: Service and Repair
REPLACEMENTHINT: Installation is in the reverse order of removal. But, the installation is indicated only when it has a point.
1. REMOVE FRONT PILLAR GARNISH LH
2. REMOVE FRONT PILLAR GARNISH RH
3. REMOVE LH VISOR ASSEMBLY
4. REMOVE RH VISOR ASSEMBLY
5. REMOVE VISOR HOLDER
6. REMOVE COURTESY LENS
7. REMOVE ROOF CONSOLE BOX ASSEMBLY (W/O SLIDING ROOF)
8. REMOVE ROOF CONSOLE L/RELAY BOX ASSEMBLY (W/ SLIDING ROOF)
9. REMOVE ASSIST GRIP SUB-ASSEMBLY
10. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP LH
11. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP RH
12. REMOVE ROOF HEADLINING ASSEMBLY
a. Remove the roof headlining assembly within the range that the window shield glass can be removed.
13. REMOVE FR WIPER ARM RH
14. REMOVE FR WIPER ARM LH
15. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY
16. REMOVE WINDSHIELD MOULDING OUTSIDE LH
a. Put protective tape.
b. Using a screwdriver, removed the clip.
c. Using a screwdriver, removed the hooks and windshield moulding outside LH.
17. REMOVE WINDSHIELD MOULDING OUTSIDE RH
18. REMOVE WINDSHIELD OUTSIDE MOULDING CLIP NO.1
a. Using a drill of less than 4 mm (0.16 in.).
b. Gently and vertically place the drill tip onto the rivet, and cut the rivet flanges.
A: 5 mm (0.20 in.)
NOTE:
- Prizing the hole with a drill can lead to damage to the rivet hole or the drill itself.
- Be careful when undertaking this task as the cut rivet is hot.
c. Even if flange is taken off, continue drilling and push cut remaining fragment with the drill.
d. Removed the windshield outside moulding clip No.1.
19. REMOVE WINDSHIELD MOULDING OUTER UPPER
a. Using a knife, cut off the windshield moulding outer upper as shown in the illustration.
NOTE: Do not damage the body with the knife.
20. REMOVE INNER REAR VIEW MIRROR ASSEMBLY
a. Remove the inner rear view mirror assembly as shown in the illustration.
21. REMOVE WINDSHIELD GLASS
a. Disconnect the connector (with front wiper deicer).
b. Push a piano wire through between the body and glass from the interior.
c. 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 exterior ornaments as shown in the illustration.
- To prevent scratching the safety pad when removing the windshield, place a plastic sheet between the piano wire and safety pad.
d. Cut the adhesive by pulling the piano wire around it.
e. Remove the glass.
NOTE: Leave as much adhesive on the body as possible when cutting off the glass.
22. CLEAN WINDSHIELD GLASS
a. Using a scraper, remove the damaged stoppers, dam and adhesive sticking to the glass.
b. Clean the glass with cleaner.
NOTE:
- Do not touch the glass after cleaning it.
- Be careful not to damage the body.
23. INSTALL WINDSHIELD GLASS STOPPER NO.1
a. Install 2 new stoppers onto the glass as shown in the illustration.
A: 9 mm (0.35 in.)
24. INSTALL WINDSHIELD GLASS STOPPER NO.2 (W/ OUTER MIRROR HEATER)
a. Install 2 new stoppers onto the glass as shown in the illustration.
A: 7 mm (0.28 in.)
25. INSTALL WINDSHIELD GLASS STOPPER NO.1 (W/ OUTER MIRROR HEATER)
26. INSTALL WINDOW GLASS ADHESIVE DAM
a. Install new window glass adhesive dam as shown in the illustration.
a: 7 mm (0.28 in.)
b: 37 mm (1.46 in.)
27. INSTALL WINDOW GLASS ADHESIVE DAM NO.2
28. INSTALL WINDSHIELD GLASS
a. Clean and shape contact surface of body
1. Using a knife, cut away any rough areas on the body.
HINT: Leave as much of the adhesive on the body as possible.
2. 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.
b. Position glass
1. Place the glass in the correct position.
2. Check that all contacting parts of the glass rim are perfectly even.
3. Place reference marks between the glass and body.
4. Remove the glass.
c. Coat contact surface of body with Primer M
1. 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.
d. Coat contact surface of glass with Primer G
1. Using a brush or sponge, coat the edge of the glass and the contact surface with Primer G.
2. 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
e. Apply adhesive
1. Cut off the tip of the cartridge nozzle.
2. Load the sealer gun with the cartridge.
3. Coat the glass with adhesive, as shown in the illustration.
A: 8 mm (0.31 in.)
B: 12 mm (0.47 in.)
f. Install glass
1. Position the glass so that the reference marks are lined up, and press in gently along the rim.
2. Using a spatula, apply adhesive on the glass rim.
3. Using a scraper to remove any excess or protruding adhesive.
4. Hold the windshield glass in place securely with a protective tape or equivalent until the adhesive hardness.
29. INSTALL WINDSHIELD MOULDING OUTER UPPER
a. Place new moulding onto the body and tap it by hand.
30. WATER-LEAK CHECK AND REPAIREMENT
a. Conduct a leak test after the hardening time has elapsed.
b. Seal any leak with sealant.
31. INSTALL WINDSHIELD OUTSIDE MOULDING CLIP NO.1
a. Using an air riveter or hand riveter with nose piece, strike rivets into the body panel to install the windshield outside moulding clip No.1 to the body panel.
NOTE:
- If the rivet is not positioned perpendicularly it will bend the mandrel.
- When trigger is then pulled, it may damage SST.