WINDSHIELD GLASS INSTALLATION

PROCEDURE


  1. CLEAN WINDSHIELD GLASS

    A005HUF

    1. Using a scraper, remove the adhesive tape and adhesive sticking to the windshield glass.

      Note

      Be careful not to damage the windshield glass.

    2. Clean the outer circumference of the windshield glass with a non-residue solvent.

      Note

      Do not touch the windshield glass surface after cleaning it.

  2. INSTALL NO. 1 WINDSHIELD GLASS STOPPER (for 2-piece Type)

    A005L6OE01
    Text in Illustration
    *1 No. 1 Windshield Glass Stopper

    1. Install new 2 No. 1 windshield glass stoppers to the vehicle body, as shown in the illustration.

  3. INSTALL WINDSHIELD GLASS STOPPER (for 2-piece Type)


    1. Using a brush, coat the application area of the windshield glass stoppers with Primer.

      Note

      Do not apply too much primer.

    2. Install new 2 windshield glass stoppers onto the windshield glass, as shown in the illustration.

      A005K7FE02
      Text in Illustration
      *a Back Side *b Ceramic Notch
      Standard Dimension:
      Area Dimension
      a 9.5 mm (0.3740 in.)
      b 30.0 mm (1.1811 in.)

      Note


      • Allow the primer to dry for 3 minutes or more.

      • Throw away any leftover primer.

      Tech Tips


      • If an area other than that specified is coated by accident, wipe off the primer with a clean piece of cloth before it dries.

  4. INSTALL WINDSHIELD OUTSIDE MOULDING


    1. Using a brush, coat the application area of the windshield outside moulding with primer.

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      Text in Illustration
      A005HNR Primer - -

      Note


      • Do not apply too much primer.

    2. Apply double-sided tape to the windshield outside moulding.

      A005IU2E01
      Text in Illustration
      A005HNR Double-Sided Tape - -

    3. Using a brush, coat the application area of the upper windshield outside moulding with primer.

      Note


      • Do not apply too much primer.

    4. Install a new windshield outside moulding onto the windshield glass, as shown in the illustration.

      A005JTXE01
      Text in Illustration
      *1 Windshield Outside Moulding - -
      *a Back Side - -

  5. INSTALL WINDOW GLASS ADHESIVE DAM


    1. Using a brush or a sponge, coat the application area of the windshield glass adhesive dam with primer.

      Note

      Do not apply too much primer.

    2. Install a new adhesive dam onto the windshield glass, as shown in the illustration.

      A005LGGE02
      Text in Illustration
      *a Back Side *b Dam Reference Line

      Note

      Allow the primer to dry for 3 minutes or more.

  6. INSTALL WINDSHIELD GLASS

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    1. Clean and shape the contact surfaces of the vehicle body.


      1. Using a knife, cut away excess adhesive on the contact surfaces of the vehicle body, as shown in the illustration.

        Text in Illustration
        A005HNR Adhesive

        Note

        Leave as much adhesive on the vehicle body as possible.

      2. Clean the contact surfaces of the vehicle body with a piece of cloth saturated with cleaner.

    2. A005J3LE01
      Text in Illustration
      *a Matchmark

      Position the windshield glass.


      1. Using suction cups, place the windshield glass in the correct position.

      2. Check that the whole contact surface of the windshield glass rim is perfectly even.

      3. Align the matchmarks on the windshield glass and vehicle body.

        Note

        Check that the windshield glass stoppers are attached to the vehicle body correctly.

      4. Remove the windshield glass.

      5. Using a brush, coat the installation surface on the vehicle body with primer.

        Note


        • Do not coat the adhesive with primer.

        • Do not apply too much primer.

        • Allow the primer to dry for 3 minutes or more.

        • Throw away any leftover primer.

      6. Using a brush, coat the application area of adhesive with primer.

        Note

        Do not apply too much primer.

        A005JDUE02
        Text in Illustration
        *a Back Side - -
        A005HNR Primer - -
        Standard Dimension:
        Area Dimension
        a 9.0 mm (0.3543 in.)
        b 19.0 mm (0.7480 in.)

    3. Cut off the tip of the cartridge nozzle as shown in the illustration.

    4. Load the sealer gun with cartridge.

    5. Apply adhesive to the windshield glass, as shown in the illustration.

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      Text in Illustration
      *1 Sealer Gun - -
      *a Back Side *b Adhesive Center Line
      A005HNR Adhesive - -
      Standard Dimension:
      Area Dimension
      a 8.0 mm (0.3150 in.)
      b 12.0 mm (0.4724 in.)
      c 4.0 mm (0.1575 in.)

      Note

      Allow the primer to dry for 3 minutes or more.

    6. A005J3LE01

      Install the windshield glass assembly.


      1. Using suction cups, position the windshield glass so that the matchmarks are aligned, and install the windshield glass .

        Text in Illustration
        *a Matchmark

        Note


        • Allow the primer to dry for 3 minutes or more.

        • Check that the windshield glass stoppers are attached to the vehicle body correctly.

        • Check the clearance between the vehicle body and windshield glass.

      2. Lightly press the front surface of the windshield glass to ensure that the windshield glass is securely fit to the vehicle body.

        Tech Tips

        Press the glass with a force of 98 N (10 kgf, 22 lbf) or more.

      3. A005KBS

        Using a scraper, remove any excess or protruding adhesive.

        Text in Illustration
        A005L3V Adhesive

        Note

        Apply adhesive onto the windshield glass rim.

      4. Hold the windshield glass using protective tape until applied adhesive becomes hard.

  7. INSPECT FOR LEAK AND REPAIR


    1. After the adhesive has hardened, apply water from the outside of the vehicle. Check that no water leaks into the cabin.

    2. If water leaks into the cabin, allow the water to dry and add adhesive.

    3. Remove the protective tape.

  8. INSTALL ROOF HEADLINING ASSEMBLY


    1. Return the front section of the roof headlining assembly to the original position Click here.

  9. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

    Click here

  10. INSTALL FRONT NO. 2 FENDER TO COWL SIDE SEAL LH

    Click here

  11. INSTALL FRONT NO. 2 FENDER TO COWL SIDE SEAL RH

    Click here

  12. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY

    Click here

  13. INSTALL FRONT WIPER ARM HEAD CAP

    Click here