Windshield: Service and Repair

REMOVAL




1. REMOVE INNER REAR VIEW MIRROR
Remove the inner rear view mirror as shown in the illustration.

2. REMOVE ASSIST GRIPS
a. Using a screwdriver, remove the caps.

HINT: Tape the screwdriver tip before use.




b. Driver's side:
Using a torx driver, remove the 2 torx screws and assist grip.

Torx driver: T30 (Part No.09041-00030 or locally manufactured tool)

c. Passenger's side:
Using a torx driver, remove the 4 torx screws and 2 assist grips.

Torx driver: T30 (Part No.09041-00030 or locally manufactured tool)

3. REMOVE FRONT PILLAR GARNISH




a. Using a screwdriver, remove the front pillar garnish.

HINT: Tape the screwdriver tip before use.

b. Employ the same manner described above to the other side.

4. REMOVE SUN VISORS
a. Remove the 4 screws and 2 sun visors.
b. w/ Light:
Disconnect the connector.

5. REMOVE SUB-VISORS
Remove the 4 screws and 2 sub-visors.

6. REMOVE FRONT PERSONAL LIGHT




a. Using a screwdriver, remove the left side lens.

HINT: Tape the screwdriver tip before use.




b. Remove the 2 screws.
c. Using a screwdriver, rotate the clip by 90 degrees and remove it.

HINT: Tape the screwdriver tip before use.

d. Remove the front personal light, then disconnect the connector.

7. REMOVE SUN VISOR HOLDERS
Remove the 2 screws and 2 sun visor holders.

8. REMOVE FRONT PART OF ROOF HEADLINING
9. REMOVE WIPER ARMS
a. Using a screwdriver, remove the 2 caps.

HINT: Tape the screwdriver tip before use.

b. Remove the 2 nuts and wiper arms.

10. REMOVE COWL LOUVER
Remove the 8 screws, 6 clips and cowl louver.

11. REMOVE FRONT PART OF ROOF SIDE RAIL WEATHERSTRIP LH AND RH
Pull the front part of roof side rail weatherstrip LH and RH to remove it.

12. REMOVE WINDSHIELD OUTSIDE MOULDING




a. Remove the 4 screws and windshield outside moulding.
b. Employ the same manner described above to the other side.

13. REMOVE WINDSHIELD OUTSIDE UPPER MOULDING




a. Using a knife, cut off the moulding as shown in the illustration.

NOTE: Do not damage the body with the knife.

b. Remove the remaining moulding.

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 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 off 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 shop rag saturated in cleaner.

HINT: Even if all the adhesive has been removed, clean the body.

2. CLEAN REMOVED GLASS




a. Remove the damaged stoppers and dam.
b. Using a scraper, remove the adhesive sticking to the glass.
c. Clean the glass with cleaner.

NOTE: Do not touch the glass after cleaning it.




3. INSTALL NEW STOPPERS
Attach new stoppers to the glass with the ceramic notches on the glass aligned with the stoppers as shown in the illustration.




4. INSTALL NEW DAM
Install a new dam with double-stick tape as shown in the illustration.

A: 7.0 mm (0.276 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 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 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 in the illustration.

A: 12 mm (0.47 in.)
B: 8 mm (0.31 in.)

10. INSTALL WINDSHIELD GLASS AND MOULDING




a. Install the glass, aligning the reference marks using a suction rubber.

HINT: Check that stoppers engage correctly viewing.

b. Lightly press the glass front surface for close contact.




c. Correct insufficient or protruded adhesive agent using a spatula.

HINT: Apply the adhesive agent up to the windshield glass edge.




d. Install a new windshield outside upper moulding to the windshield glass before the adhesive agent hardens.
e. Using a scraper, remove any excessive adhesive agent before it hardens.
f. Hold the glass and moulding in place securely with a protective tape or equivalent until the adhesive hardened.

NOTE: Take care not to drive the vehicle during the time described in the table.




11. INSPECT FOR LEAKAGE AND REPAIR

NOTE: Conduct a leak test after the hardening time has elapsed.

12. INSTALL WINDSHIELD OUTSIDE MOULDING




a. Install the 4 screws and windshield outside moulding.
b. Employ the same manner described above to the other side.

13. INSTALL FRONT PART OF ROOF SIDE RAIL WEATHERSTRIP LH AND RH
Install the front part of roof side rail weatherstrip LH and RH.

14. INSTALL COWL LOUVER
Install the cowl louver with the 8 screws and 6 clips.

15. INSTALL WIPER ARMS
a. Operate the wipers 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 shown in the illustration.

A: Approx. 25.7 mm (1.012 in.)
B: Approx. 39.7 mm (1.563 in.)

HINT: When installing wiper arms, make sure that the tips of the blades are not beyond the ceramic edge as indicated by "C" part in the illustration.

d. Torque the nuts.

Torque: 20 N.m (204 kgf.cm, 15 ft.lbf)

e. Install the caps.

16. INSTALL FRONT PART OF ROOF HEADLINING
17. INSTALL SUN VISOR HOLDERS
Install the 2 sun visor holders with the 2 screws.

18. INSTALL FRONT PERSONAL LIGHT
a. Connect the connector, then install the front personal light.
b. Install the 2 screws and the clip.

HINT: When installing the front personal light, attach the clip to the housing and push it to the bracket.

c. Install the left side lens.

19. INSTALL SUB-VISORS
Install the 2 sub-visors with the 4 screws.

20. INSTALL SUN VISORS
a. w/ Light:
Connect the connector.

b. Install the 2 sun visors with the 4 screws.

21. INSTALL FRONT PILLAR GARNISH




a. Install the front pillar garnish.
b. Employ the same manner described above to the other side.

22. INSTALL ASSIST GRIPS




a. Driver's side:
Using a torx socket wrench, install the assist grip with the 2 torx screws.

Torx driver: T30 (Part No. 09041-00030 or locally manufactured tool)

b. Passenger's side:
Using a torx socket wrench, install the 2 assist grips with the 4 torx screws.

Torx driver: T30 (Part No. 09041-00030 or locally manufactured tool)

c. Install the caps.




23. INSTALL INNER REAR VIEW MIRROR
Install the inner rear view mirror as shown in the illustration.