Windshield: Service and Repair
REMOVAL1. REMOVE FRONT DOOR OPENING TRIMS
2. REMOVE FRONT ASSIST GRIP
a. Using a screwdriver, remove the 2 assist grip plugs, then remove the 2 screws and the front assist grip.
HINT: Tape up the screwdriver tip before use.
b. Use the same manner described above to the other side.
3. REMOVE FRONT PILLAR GARNISH
a. Using a screwdriver, remove the front pillar garnish.
HINT: Tape up the screwdriver tip before use.
b. Use the same manner described above to the other side.
4. REMOVE SUN VISOR
a. Using a screwdriver, remove the caps.
HINT: Tape up the screwdriver tip before use.
b. Remove the screws, then disconnect the connectors.
c. Remove the sun visors.
5. REMOVE DOUBLE VISOR
Remove the screws and the double visors.
6. REMOVE HOLDER
Remove the screws and the holders.
7. REMOVE OVERHEAD CONSOLE BOX
a. Remove the bolt.
b. Using a screwdriver, remove the overhead console box, then disconnect the connector.
HINT: Tape up the screwdriver tip before use.
8. REMOVE ASSIST GRIPS
9. PULL DOWN FRONT SIDE OF ROOF HEADLINING
10. REMOVE INNER REAR VIEW MIRROR
a. Disconnect the connector.
b. Unfasten a screw, and remove the other screw and the inner rear view mirror.
11. REMOVE WIPER ARMS
a. Remove the 2 wiper arm head caps and the 2 nuts.
b. Remove the 2 wiper arms.
12. REMOVE HOOD TO COWL TOP SEAL
13. REMOVE COWL TOP VENTILATOR LOUVERS
a. Remove the cowl top ventilator louver RH.
b. Remove the cowl top ventilator louver LH.
14. REMOVE OUTSIDE NO. 2 MOULDING
a. Using a screwdriver, remove the outside No. 2 moulding.
HINT: Tape up 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. Use the same manner described above to the other side.
15. 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.
16. 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 from scratching when removing the windshield, place a plastic sheet between the piano wire and the safety pad.
c. Cut the adhesive by pulling the piano wire around it.
d. Remove the windshield 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 adhesive on the body as possible.
b. Clean the cutting surface of the adhesive with a piece of shop rag dampen with cleanser.
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 cleanser.
NOTE:
- Do not touch the glass surface after cleaning it.
- Be careful not to damage the glass.
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.
A: 7 mm (0.28 in.)
B: 20 mm (0.79 in.)
NOTE: Do not touch the glass surface after cleaning it.
5. POSITION GLASS
a. Place the 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 the body.
d. Remove the glass.
6. CLEAN CONTACT SURFACE OF GLASS
Using cleanser, clean the contact surface which is black-colored area around the entire glass rim.
NOTE: Do not touch the glass surface after cleaning it.
7. COAT CONTACT SURFACE OF BODY WITH PRIMER "M"
Using a brush, apply Primer M to the exposed part of the body on the vehicle side.
NOTE:
- Let the primer coating dry for more than 3 minutes.
- Do not coat Primer M to the adhesive.
- Do not keep remaining Primer M for later use.
8. COAT CONTACT SURFACE OF GLASS WITH PRIMER "G"
a. Using a brush or sponge, coat the edge of the glass and the contact surface with Primer G.
b. If the primer is coated wrongly to the area not specified by accident, wipe it off with a clean shop rag before the primer dries.
NOTE:
- Let the primer coating dry for more than 3 minutes.
- Do not keep remaining 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, finish up 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 WINDSHIELD 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: Make sure 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.
NOTE: Take care not to drive the vehicle within the time described in the table.
11. INSPECT FOR LEAK AND REPAIR
a. Conduct a leak test after the adhesive dried completely.
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 NO. 2 MOULDING
a. Using an air riveter with nose piece No. 4, install 4 new rivets and the outside No. 2 moulding.
HINT: Before using the air riveter with nose piece No. 4, cut 5 mm (0.20 in.) from the edge of nose piece No. 4 as shown in the illustration.
NOTE:
- Do not prize a riveter. It could damage the riveter and cause loose fitting and mandrel bend.
- Do not tilt the riveter when fasten the rivet to the material to avoid loose fitting.
- Do not allow gap spacing between the rivet head and the material.
- Do not allow gap spacing between the materials.
b. Use the same manner described above to the other side.
15. INSTALL COWL TOP VENTILATOR LOUVERS
a. Install the cowl top ventilator louver LH.
b. Install the cowl top ventilator louver RH.
16. INSTALL HOOD TO COWL TOP SEAL
17. INSTALL WIPER ARMS
a. Operate the wiper motor once and turn the wiper switch OFF.
b. Install the wiper arms and tighten the nuts by hand.
c. Adjust the installation positions of the wiper arms to the positions as shown in the illustration.
A: Approx. 33 mm (1.30 in.)
B: Approx. 21 mm (0.83 in.)
d. Torque the nuts.
Torque: 20 N.m (204 kgf.cm, 15 ft.lbf)
e. Install the 2 wiper arm head caps.
18. INSTALL INNER REAR VIEW MIRROR
a. Install the inner rear view mirror with the 2 screws.
b. Connect the connector.
19. INSTALL FRONT SIDE OF ROOF HEADLINING
20. INSTALL ASSIST GRIPS
21. INSTALL OVERHEAD CONSOLE BOX
Connect the connector, then install the overhead console box with the bolt.
22. INSTALL HOLDER
Install the holders with the screws.
23. INSTALL DOUBLE VISOR
Install the double visors with the screws.
24. INSTALL SUN VISOR
a. Install the sun visors with the screws, then connect the connectors.
b. Install the caps.
25. INSTALL FRONT PILLAR GARNISH
a. Install the front pillar garnish.
b. Use the same manner described above to the other side.
26. INSTALL FRONT ASSIST GRIP
a. Install the front assist grip with the 2 screws, then install the 2 assist grip plugs.
b. Use the same manner described above to the other side.
27. INSTALL FRONT DOOR OPENING TRIMS