Windshield Glass: Installation

Cleaning of windshield glass

When the windshield glass is reused.
1. Using a scraper or similar tool, remove the adhesive and/or double-sided tape remaining on the windshield glass.
  CAUTION: Do not damage the windshield glass.

Using the appropriate cleaner, clean the rim of the windshield glass.

CAUTION: New windshield glass also needs to be cleaned.

Courtesy of SUBARU OF AMERICA, INC.

Installation of windshield outside molding

Apply primer to the installation area for the windshield outside molding on the windshield glass.

Primer: 3M N-200, Sunstar #GP402, or equivalent

CAUTION: Apply the primer to the ceramic part only.

Courtesy of SUBARU OF AMERICA, INC.

Standard value

STANDARD VALUE SPECIFICATION

Part	Dimension
a	7mm {0.276in}

After the primer has been dried, align the windshield outside molding with both side of the windshield glass.

Using a roller, crimp the windshield outside molding in the direction specified by the arrows in the figure.

Standard value: 50N/100 mm {5.1 kgf/3.94 in} {11.2 lbf/3.94 in}

CAUTION: Be careful to attach the windshield outside molding firmly so that there is no loose or undulating part.

Courtesy of SUBARU OF AMERICA, INC.

Using a roller, crimp the windshield outside molding in the direction specified by the arrows in the figure.

Standard value: 50N/100 mm {5.1 kgf/3.94 in} {11.2 lbf/3.94 in}

CAUTION: Be careful to attach the windshield outside molding firmly so that there is no loose or undulating part.

Courtesy of SUBARU OF AMERICA, INC.

INSTALL UPPER WINDSHIELD GLASS SEAL

Install the upper windshield glass seal to the windshield outside molding, as shown in the illustration.

Courtesy of SUBARU OF AMERICA, INC.

Standard Dimension

STANDARD DIMENSION SPECIFICATION

Area	Dimension
a	165 mm {6.496 in}
b	3.0 mm {0.118 in}
c	5.7mm {0.224 in}
d	5.0 mm {0.197 in}
e	0 to 0.5 mm {0 to 0.020 in}
f	7.3 mm {0.287in}
g	6.8 mm {0.268 in}

INSTALL WINDOW GLASS ADHESIVE DAM

Using the appropriate cleaner, clean the installation surface of the window glass adhesive dam.

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

Courtesy of SUBARU OF AMERICA, INC.

Standard Dimension

STANDARD DIMENSION SPECIFICATION

Area	Dimension
a	13.0 mm {0.512 in}
b	15.3 mm {0.602 in}
c	0 to 3.0mm {0 to 0.118 in}
d	14.8 mm {0.583 in}

NOTE: Use the same procedure for both the RH and LH sides.

INSTALL LOWER WINDSHIELD GLASS SEAL

Using the appropriate cleaner, clean the installation surface of the windshield glass seal.

Install the new lower windshield glass seal onto the windshield glass, as shown in the illustration.

Courtesy of SUBARU OF AMERICA, INC.

Standard Dimension

STANDARD DIMENSION SPECIFICATION

Area	Dimension
a	28.0 mm {1.102 in}

CAUTION: Install the window glass seal so that it does not protrude onto the glass surface.

NOTE: Use the same procedure for both the RH and LH sides.

Installation of windshield glass

Cleaning of mounting surface of the body

Remove the adhesive layer on the body using cutter knife or similar tool to obtain smooth surface of 2 mm {0.08 in} thick.

CAUTION:

Do not damage the body.
Always leave a little amount of adhesive.

Courtesy of SUBARU OF AMERICA, INC.

Standard value

STANDARD VALUE SPECIFICATION

Part	Dimension
a	2.0 mm {0.079in}

Using the appropriate cleaner, clean the installation surface of the body.

Windshield glass pre-installation work

Attach the suction rubber onto the windshield glass.

Place the windshield glass on the body temporary, and set them so that windshield glass's upper end and both side have same width (consistent clearance between body and windshield glass edge).

Standard value

STANDARD VALUE SPECIFICATION

Part	Dimension
a	4.0 mm {0.157in}
b	5.0 mm {0.197in}

Courtesy of SUBARU OF AMERICA, INC.

Apply packing tapes or similar tapes on the windshield glass and body panel, and put alignment marks on them with a pen for reinstallation. (When new glass is used.)

Courtesy of SUBARU OF AMERICA, INC.

CAUTION: From inside the vehicle, check that windshield glass stoppers and body are engaged.

NOTE: When windshield glass will be reused, check and correct the position of the alignment marks.

Detach the windshield glass.
Apply primer on the body surface.
Primer: The Dow Automotive U-413 or equivalent

CAUTION: Do not apply the primer thickly.

Apply primer onto backside of the windshield glass, where indicated in the figure.

Primer: The Dow Automotive U-401, U402 or equivalent

CAUTION: Do not apply the primer thickly.

Courtesy of SUBARU OF AMERICA, INC.

Standard value

STANDARD VALUE SPECIFICATION

Part	Dimension
a	8.0 mm {0.315in}

Cut the tip of the adhesive nozzle, as shown in the figure.

Standard value

STANDARD VALUE SPECIFICATION

Part	Dimension
a	2.0 mm {0.029in}
b	8.0 mm {0.315in}
c	9.0 mm {0.354in}

Courtesy of SUBARU OF AMERICA, INC.

Set the adhesive into the sealant gun.
Adhesive: The Dow Automotive ESSEX U-400HV or equivalent

Apply a bead of adhesive as shown in below.

CAUTION: Apply adhesive after the primer dried (approx. after 10 minutes).

Courtesy of SUBARU OF AMERICA, INC.

Standard value

STANDARD VALUE SPECIFICATION

Part	Dimension
a	2.0 mm {0.079in}
b	8.0 mm {0.315in}
c	9.0 mm {0.354in}
d	11.3 mm {0.445in}
e	22.0 mm {0.866in}
f	30.0 mm {1.181in}
g	10.8 mm {0.425in}

Installation of windshield glass

Holding the suction rubbers, position the alignment marks and install the windshield glass.

Courtesy of SUBARU OF AMERICA, INC.

CAUTION:

After body side primer is dried (approx. 10 minutes), attach the windshield glass.
From inside the vehicle, check that windshield glass stoppers and body are engaged.

Lightly press the front side of the windshield glass to fit tightly.
NOTE: Pressing force: 98 N {10 kgf} {22.0 lbf} or more
Using protection tapes or similar tapes, hold the windshield glass until the adhesive cures completely.
NOTE: For minimum drying time or waiting time after the cure of adhesive, consult the instruction or manual of each adhesive supplier.

Leak test and repair
1. After the adhesive cure, pour water over the vehicle and make sure no water leak inside.
2. If any water leak is found, fill the three cement black after the drying.
3. Remove the applied protective tape and packing tape.
Installation of roof head lining ASSY
1. Install the roof head lining ASSY front side (parts). (Refer to INSTALLATION )
Installation of the cowl ventilator louver (Refer to INSTALLATION )
Installation of the front fender to cowl side seal LH
Installation of the front fender to cowl side seal RH
NOTE: Install the part in the same manner as LH side.
Installation of the front wiper arm & blade ASSY RH (Refer to INSTALLATION )
Installation of the front wiper arm & blade ASSY LH (Refer to INSTALLATION )
Installation of the wiper arm head caps (Refer to INSTALLATION )