9E
Windshield Removal and Installation
Reference: Windshield Construction
Removal
1) Clean both inside and outside of glass and around it.
2) Remove wiper arms and garnish.
3) Using tape, cover body surface around glass to prevent any damage.
4) Remove rear view mirror, sun visor and front pillar trims (right & left).
5) If necessary, remove instrument panel. Refer to Instrument Panel Removal and Installation .
6) If necessary, remove head lining.
7) Remove (or cut) windshield molding all around until windshield edge comes out.
8) Drill hole with eyeleteer (1) through adhesive and let piano string through it.
9) Cut adhesive all around windshield (1) with piano string (2). When using tool to cut adhesive, be careful not to cause damage to windshield. Use wire to cut adhesive along lower part of windshield.
NOTE:
Use piano string as close to glass as possible so as to prevent damage to body and instrument panel.
3. Windshield knife
10) Using knife (1), smoothen adhesive (2) remaining on body side (3) so that it is 1 – 2 mm (0.039 – 0.078 in.) thick all around.
NOTE:
Before using knife, clean knife with alcohol or the like to remove oil.
11) When reusing windshield, remove the adhesive (1) from the windshield, using care not to damage primer coated surface (2).
Installation
1) Using cleaning solvent, clean windshield edge where windshield glass is to be adhered. (Let it dry for more than 10 minutes.)
2) Install new glass stoppers (1) (2 pieces) to lower side of windshield.
3) To determine installing position of glass (2) to body (3), position glass against body so that clearance between upper end of glass and body is approximately 5 mm (0.197 in.) and clearances between each side end (right & left) of glass and body are even. Place glass so that lug of fastener is matched with cut in body and fit fastener. Then mark mating marks (1) on glass and body as shown. Upper clearance can be adjusted by moving glass stoppers position.
Windshield clearance
“a”: approx. 5 mm (0.197 in.)
4. Molding
4) Clean contact surfaces of old adhesive (4), paint or bare metal thoroughly.
If surfaces of paint or bare metal come out, apply primer (2) for body with caution not to apply primer to surface of adhesive remaining on body.
NOTE:
• Be sure to refer to primer maker's instruction for proper handling and drying time.
• Do not touch body and old adhesive surfaces where glass is to be adhered.
1. Do not apply primer
3. Apply primer
5) Install new molding (1) to glass (2).
6) Clean glass surface to be adhered to body with clean cloth. If cleaning solvent is used, let it dry for more than 10 minutes.
Cleaning area for distance from the edge of glass or molding
“a”: 30 – 50 mm (1.18 – 1.97 in.)
7) Install new spacer (1) to glass (4).
2. Ceramic printing
3. Cutting section of ceramic printing
8) Using new brush, apply sufficient amount of primer for glass along glass surface to be adhered to body.
NOTE:
• Be sure to refer to maker's instruction for proper handling and drying time.
• Do not apply primer on outside of ceramic coated surface.
• Do not touch primer coated surface.
• Width “b”: 15 mm (0.59 in.)
9) Apply primer for molding (1) along molding surface all around as shown in the figure.
Width applied primer for windshield
“b”: 15 mm (0.59 in.)
2. Fastener
10) Apply adhesive referring to the figure.
NOTE:
• Start from bottom side of glass.
• Be careful not to damage primer.
• Height of adhesive applied to lower side should be higher than that of other three sides.
• Upper, right and left sides.
• Press glass against body quickly after adhesive is applied.
• Use of rubber sucker grip is helpful to hold and carry glass after adhesive is applied.
• Perform Steps 8) to 9) within 10 min. to ensure sufficient adhesion.
• Be sure to refer to adhesive maker's instruction for proper handling and drying time.
Adhesive amount specifications and position for windshield
Width “d”: Approx. 8 mm (0.31 in.)
Height “e”: Approx. 9 mm (0.35 in.)
Position “f”: Approx. 15 mm (0.59 in.)
Position “g”: Approx. 17 mm (0.67 in.)
Distance “h”: Approx. 10.5 mm (0.41 in.)
1. Molding 2. Adhesive 3. Glass
11) Holding rubber sucker grips (1), place glass onto body by aligning mating marks marked in Step 3) and press it.
12) Check for water leakage by pouring water over windshield through hose. If leakage is found, dry windshield and fill leaky point with adhesive. If water still leaks even after that, remove glass and start installation procedure all over again.
NOTE:
• Do not use high pressure water.
• Do not blow compressed air directly at adhesive applied part when drying.
• Do not use infrared lamp or like for drying.
CAUTION:
Upon completion of installation, note the following.
• Sudden closing of door before adhesive is completely set may cause glass to become loose or to come off. Therefore, if door is opened or closed before adhesive is completely set, make sure to open all door glasses and use proper care.
• If molding is not securely in place, hold it down with a tape until adhesive is completely set.
• Each adhesive has its own setting time.
• Be sure to refer to its maker's instruction, check setting time of adhesive to be used and observe precautions to be taken before adhesive is set.
• Refrain from driving till adhesive is completely set so as to ensure proper and sufficient adhesion.