Subaru BRZ 2013 · Service Manual Exterior body & electrical

Windshield glass

Components Removal / installation

GLASS & WINDOW

WINDSHIELD GLASS

EXPLODED VIEW

REMOVAL

1. Precautions for the removal / installation of the windshield glass

(1) If working with piano wire, remove the front pillar garnish first, mount the protect cover on the curtain shield airbag, then begin the removal / installation of the windshield glass.

2. Removal of the wiper arm head caps (Refer to

)

3. Removal of the front wiper arm & blade ASSY LH (Refer to

)

4. Removal of the front wiper arm & blade ASSY RH (Refer to

)

5. Removal of front fender to cowl side seal LH (Refer to

)

6. Removal of the front fender to cowl side seal RH

NOTE:

Remove the part in the same manner as LH side.

7. Removal of the cowl ventilator louver (Refer to

)

8. Removal of roof head lining ASSY

(1) Partially detach the front side of the roof head lining ASSY in an area required for removing/installing the windshield glass. (Refer to

)

CAUTION:

Be careful not to damage the roof head lining ASSY.

9. Removal of windshield glass

CAUTION:

·Work with the windshield knife or piano wire according to cut location and/or condition.
·Use the suction rubber to keep the windshield glass in place from outside to avoid dropping the windshield glass during operation.
·Be careful not to damage the windshield glass because the windshield glass stopper is attached on the windshield glass.

(1) Apply protective tape to the body side of the circumference of windshield glass.

Captions in illustration

*1	Protective tape

(2) Using the cutter knife, cut the windshield outside molding.

·Do not damage the windshield glass and the body surface.
·If the body surface is damaged, remove the windshield glass, and then perform the rust prevention treatment.

Captions in illustration

*1	Windshield outside molding
*a	Cut

(3) When the windshield glass is reused.

Captions in illustration

*a	Alignment marks

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

(4) Attach the suction rubber onto the windshield glass.

(5) When using the windshield knife

(a) Apply sufficient amount of soapy water to the adhesive section.

(b) Insert the windshield knife into the adhesive section.

(c) Using the windshield knife, insert the blade between the windshield glass and the vehicle body, and move the knife along the edge of the glass to cut adhesive while keeping the blade at right angle with the edge.

·Never twist the windshield glass knife.
·Do not damage the windshield glass.

Begin from where the windshield glass and the body is most distant.

Captions in illustration

*1	Windshield glass stopper
*2	Windshield knife
*3	Protective tape
*a	Align with the glass

(6) When using piano wire

(a) Using an air drill, make a hole in the adhesive section and pass the piano wire through the hole.

(b) Pass the piano wire (0.6 mm {0.024 in} is recommended) through the point shown in the figure, attach both ends of the wire to wooden boards.

(c) Pull the piano wire both ways and cut the adhesive on the windshield glass.

·Do not tightly contact the piano wire against the windshield glass edge.
·When working around the curtain shield air bag, do not damage it with the piano wire.
·When working around the instrument panel (safety pad), apply a plastic-made guard plate for preventing any damage by the piano wire.
·Make sure do not cross the piano wires. Otherwise, they can be cut.
·Do not damage the windshield glass.

Captions in illustration

*1	Piano wire
*2	Windshield glass stopper

(7) Holding the suction rubbers, release the 2 tabs of the windshield glass stopper, then remove the windshield glass.

·Be careful not to damage the windshield glass because the windshield glass stopper is attached on the windshield glass.
·Be careful not to drop the windshield glass.

Captions in illustration

*1	Windshield glass stopper

10. Removal of window glass adhesive dam

(1) When the windshield glass is reused.

(a) Using the scraper, remove the window glass adhesive dam.

·Do not damage the windshield glass.
·The window glass adhesive dam must be replaced by a new one.

Captions in illustration

*1	Window glass adhesive dam
*a	Backside of the windshield glass

11. Removal of windshield glass seal

(1) When the windshield glass is reused.

(a) Using the scraper, remove 2 window glass seals.

·Do not damage the windshield glass.
·Windshield glass seal must be replaced by a new one.

Captions in illustration

*1	Windshield glass seal
*a	Backside of the windshield glass

12. Removal of windshield outside molding

(1) When the windshield glass is reused.

(a) Using the scraper, remove the windshield outside molding.

·Do not damage the windshield glass.
·Windshield outside molding must be replaced by a new one.

Captions in illustration

*1	Windshield outside molding
*a	Backside of the windshield glass

1. Cleaning of windshield glass

(1) When the windshield glass is reused.

(a) Using a scraper or similar tool, remove the adhesive and/or double-sided tape remaining on the windshield glass.

Do not damage the windshield glass.

(2) Using the appropriate cleaner, clean the rim of the windshield glass.

New windshield glass also needs to be cleaned.

2. Installation of windshield outside molding

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

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

Apply the primer to the ceramic part only.

Captions in illustration

*a	Backside of the windshield glass
*b	Primer application area

Part	Dimension
a	7.0 mm {0.276in}

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

(3) 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}

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

Captions in illustration

*a	Backside of the windshield glass

(4) 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}

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

Captions in illustration

*a	Backside of the windshield glass

3. INSTALL UPPER WINDSHIELD GLASS SEAL

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

Standard Dimension

Area	Dimension
a	165 mm {6.4961 in.}
b	3.0 mm {0.1181 in.}
c	5.7mm {0.2244 in.}
d	5.0 mm {0.1969 in.}
e	0 to 0.5 mm {0 to 0.0197 in.}
f	7.3 mm {0.287 in.}
g	6.8 mm {0.268 in.}

Text in Illustration

*1	Windshield Outside Molding	-	-
*a	Back Side	-	-
	Upper Windshield Glass Seal	-	-

4. INSTALL WINDOW GLASS ADHESIVE DAM

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

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

Standard Dimension

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.}

Text in Illustration

*1	Ceramic Notch	*2	Window Glass Adhesive Dam
*a	Back Side	-	-

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

5. INSTALL LOWER WINDSHIELD GLASS SEAL

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

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

Standard Dimension

Area	Dimension
a	28.0 mm {1.102 in.}

Text in Illustration

*1	Ceramic Notch	*2	Lower Windshield Glass Seal
*3	Window Glass Adhesive Dam	-	-
*a	Back Side	-	-

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

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

6. Installation of windshield glass

(1) Cleaning of mounting surface of the body

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

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

Captions in illustration

*1	Body	-	-
	Adhesive	-	-

Part	Dimension
a	2.0 mm {0.079in}

(b) Using the appropriate cleaner, clean the installation surface of the body.

(2) Windshield glass pre-installation work

(a) Attach the suction rubber onto the windshield glass.

(b) 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).

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

Captions in illustration

*1	Windshield glass
*2	Body

(c) 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.)

Captions in illustration

*a	Alignment marks

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

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

(d) Detach the windshield glass.

(e) Apply primer on the body surface.

Primer : The Dow Automotive Betaprime 5402 or equivalent

Do not apply the primer thickly.

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

Primer : The Dow Automotive Betawipe VP 04604, Betaprime 5001, or equivalent

Do not apply the primer thickly.

Captions in illustration

*a	Backside of the windshield glass	-	-
	Primer	-	-

Part	Dimension
a	8.0 mm {0.315in}

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

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

(5) Set the adhesive into the sealant gun.

Adhesive : The Dow Automotive Gurit-ESSEX Betaseal 1502 or equivalent

(6) Apply a bead of adhesive as shown in below.

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

Captions in illustration

*a	Backside of the windshield glass	-	-
	Adhesive	-	-

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}

(7) Installation of windshield glass

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

Captions in illustration

*a	Alignment marks

·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.

(b) Lightly press the front side of the windshield glass to fit tightly.

Pressing force: 98 N {10 kgf} {22.0 lbf} or more

(c) Using protection tapes or similar tapes, hold the windshield glass until the adhesive cures completely.

For minimum drying time or waiting time after the cure of adhesive, consult the instruction or manual of each adhesive supplier.

7. 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.

8. Installation of roof head lining ASSY

(1) Install the roof head lining ASSY front side (parts). (Refer to

)

9. Installation of the cowl ventilator louver (Refer to

)

10. Installation of the front fender to cowl side seal LH (Refer to

)

11. Installation of the front fender to cowl side seal RH

NOTE:

Install the part in the same manner as LH side.

12. Installation of the front wiper arm & blade ASSY RH (Refer to

)

13. Installation of the front wiper arm & blade ASSY LH (Refer to

)

14. Installation of the wiper arm head caps (Refer to

)