Windshield: Service and Repair

WINDSHIELD GLASS

REMOVAL
1. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP
2. REMOVE FRONT PILLAR GARNISH
a. Remove the assist grip.
1. Using a screwdriver, remove the 2 assist grip plugs.

HINT: Tape the screwdriver tip before use.

2. Remove the 2 screws and assist grip.

b. Remove the front pillar garnish.
c. Use the same manner described above to the other side.

3. REMOVE VISOR ASSEMBLY
4. REMOVE VISOR HOLDER

5. REMOVE ROOF CONSOLE BOX ASSEMBLY (w/ Sliding Roof)
a. Remove the 2 screws.
b. Using a screwdriver, remove the roof console box.

HINT: Tape the screwdriver tip before use.

c. Disconnect the connectors.

6. REMOVE ROOF CONSOLE BOX ASSEMBLY (w/o Sliding Roof)
a. Remove the 4 screws.
b. Using a screwdriver, remove the roof console box.

HINT: Tape the screwdriver tip before use.

c. Disconnect the connectors.

7. REMOVE INNER REAR VIEW MIRROR ASSEMBLY (w/o Electro chromic inner rear view mirror)
a. Remove the torx screw and inner rear view mirror as shown in the illustration.

8. REMOVE INNER REAR VIEW MIRROR ASSEMBLY (w/ Electro chromic inner rear view mirror)
a. Remove the mirror cover.
b. Disconnect the connector.
c. Remove the torx screw and inner rear view mirror.

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 TOP VENTILATOR LOUVER SUB-ASSEMBLY
a. Remove the hood to cowl top seal.
b. Using a clip remover, remove the 6 clips.
c. Remove the 8 screws and cowl top ventilator louver.

11. REMOVE ROOF SIDE RAIL WEATHERSTRIP
SST 09806-30010
a. Using SST, pull off the roof side rail weatherstrip from front end.

12. REMOVE WINDSHIELD OUTSIDE MOULDINGS
a. Remove the 8 screws and windshield outside mouldings.

13. REMOVE WINDSHIELD OUTER UPPER MOULDING
a. 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, be careful 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 the 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 SHARE CONTACT SURFACE OF BODY
a. Using a knife, cut away any rough areas on the body.

HINT: Leave the adhesive on the body as much as possible.

b. Clean the cut surface of the adhesive with a shop rag saturated in cleaner.

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

2. CLEAN REMOVE WINDSHIELD GLASS
a. Remove the damaged No. 2 stoppers and dams.
b. Using a scraper, remove the adhesive sticking to the glass.
c. Clean the glass with cleaner.

NOTE:
- Be careful not to damage the glass.
- Do not touch the glass face after cleaning it.

3. REPLACE NO.1 WINDSHIELD GLASS STOPPERS (w/ No. 1 stopper)
a. Remove the damaged stoppers.
b. Cut off the old adhesive around the stopper installation area.

NOTE: Be careful not to damage the body.

c. Clean the installation area.
d. Attach new stoppers to the body so that the notches on the body will align with the stoppers as shown in the illustration.

HINT: Make sure that the stoppers are installed facing the correct direction.

4. INSTALL NO.2 STOPPER
a. Attach new stoppers to the glass so that the ceramic notches on the glass will align with the stoppers as shown in the illustration.

HINT: Make sure that the stoppers are installed facing the correct direction.

A:
with No. 1 stopper: 8.0 mm (0.315 in.)
with out No. 1 stopper: 8.9 mm (0.350 in.)

5. INSTALL WINDSHIELD GLASS DAM
a. Install new dams with adhesive tape as shown in the illustration.

A: 7.0 mm (0.276 in.)

6. POSITION WINDSHIELD GLASS
a. Place the glass in the correct position.
b. Check that all contacting parts of the glass rim are set perfectly even.
c. Place reference marks on the glass and body.
d. Remove the glass.

7. CLEAN CONTACT SURFACE OF GLASS
a. 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.

8. COAT CONTACT SURFACE OF BODY WITH PRIMER "M"
a. Using a brush, coat Primer M to the exposed part of body on the vehicle side.

NOTE:
- Allow 3 minutes or more to dry the primer coated surface.
- Do not coat Primer M to the adhesive.
- Do not keep any of the opened Primer M for later use.

9. 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 as shown in the illustration.
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:
- Allow 3 minutes or more to dry the primer coated surface.
- Do not keep any of the opened Primer G for later use.

10. APPLY WINDSHIELD ADHESIVE DAM
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: 12.0 mm (0.472 in.)

B: 8.0 mm (0.315 in.)

11. INSTALL WINDSHIELD GLASS
a. Install the glass, aligning the reference marks using a suction rubber.

HINT: Check to see that the stoppers are attached to the body correctly.

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.

HINT: Install the moulding, aligning the center of moulding with the center of body.

e. 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 hardens.

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

12. INSTALL WINDSHIELD OUTER UPPER MOULDING
a. Install the glass, aligning the reference marks using a suction rubber.

HINT: Check to see that the stoppers are attached to the body correctly.

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.

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

13. INSTALL WINDSHIELD OUTSIDE MOULDING
14. INSPECT FOR LEAK AND REPAIR

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

15. INSTALL ROOF SIDE RAIL WEATHERSTRIP
a. Attach the upper edge of the weatherstrip to body flange. Tap on the weatherstrip by hand.

16. INSTALL COWL TOP VENTILATOR LOUVER SUBASSEMBLY
17. 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 positions shown in the illustration.

A: Approx. 25.4 mm (1.000 in.)

B: Approx. 40.0 mm (1.575 in.)

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

d. Torque the 2 nuts.

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

e. Install the 2 cap.

18. INSTALL INNER REAR VIEW MIRROR ASSEMBLY (w/ Electro chromic inner rear view mirror)
a. Install the inner rear view mirror and torx screw.

Torque: 2.5 N.m (25 kgf.cm, 22 in.lbf)

b. Connect the connector.
c. Install the mirror cover.

19. INSTALL INNER REAR VIEW MIRROR ASSEMBLY
a. Install the inner rear view mirror and torx screw.

Torque: 2.5 N.m (25 kgf.cm, 22 in.lbf)

20. INSTALL ROOF CONSOLE BOX ASSEMBLY
21. INSTALL VISOR HOLDER
22. INSTALL VISOR ASSEMBLY
23. INSTALL FRONT PILLAR GARNISH
24. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP