Windshield Glass: Installation

Clean the external circumference of windshield glass with alcohol or appropriate cleaning solvent.
Remove the adhesive layer on the body using cutter knife to obtain smooth face of 2 mm (0.08 in) thick.
CAUTION: Be careful not to damage the body and paint surface.

Fig 1: Identifying Adhesive Applying Area On Dam Rubber And Glass
Courtesy of SUBARU OF AMERICA, INC.
Clean the body with alcohol or appropriate cleaning solvent to eliminate cutting powder, dust and dirt completely from body.
Attach the dam rubber to the backside of the glass.
Attach the spacer to the lower end of the glass on passenger's side only.

Fig 2: Identifying Adhesive Applying Area On Dam Rubber And Spacer
Courtesy of SUBARU OF AMERICA, INC.
Install the molding to the glass.

Fig 3: Identifying Molding Applying Area On Windshield Glass
Courtesy of SUBARU OF AMERICA, INC.
1. Align the molding (A) with both ends of the upper edge of the windshield glass (C).
2. Install the molding from both corners of the upper edge toward the center.
3. Install the molding from both corners of the upper edge toward the lower side.
4. Apply the double-sided tapes (B) uniformly on both sides of the glass.
5. Attach the seal A (3) to the backside of the molding.
  
  Fig 4: Identifying Tapes And Adhesive Applying Areas On Dam Rubber, Spacer And Glass
  Courtesy of SUBARU OF AMERICA, INC.
Apply the seal B (2) to terminal section of front reinforce side panel (1) and the intersection point (3) of front reinforce side panel and front pillar out panel.

Fig 5: Identifying Seal B Applying Area On Terminal Section Of Front Reinforce Side Panel
Courtesy of SUBARU OF AMERICA, INC.
Apply two types of primers to the adhesive layer of glass using sponge.
Glass primer:

Dow Automotive's

ESSEX U-401, U-402
Apply the primer to the adhesive layer of body.
Painted surface primer:

Dow Automotive's

ESSEX U-413
NOTE:
- Primer once attached to the painted surface of the body and internal trim is hard to wipe off. Mask the circumference of such area.
- Let primer dry for about ten minutes before installing the glass.
- Do not touch the surface coated with primer.
Fig 6: Identifying Primer Applying Area On Glass And Body Side
Courtesy of SUBARU OF AMERICA, INC.
Cut off the cartridge nozzle tip as shown and set it in sealant gun.

Fig 7: Identifying Cartridge Nozzle Tip Cutting Dimensions
Courtesy of SUBARU OF AMERICA, INC.
Apply adhesive to the glass end surface as shown.
Adhesive:

Dow Automotive's

ESSEX U-400HV or equivalent

Fig 8: Identifying Adhesive Applying Area On Glass End Surface
Courtesy of SUBARU OF AMERICA, INC.
Fit the locating pins, and install windshield glass using suction rubber cup.

Fig 9: Installing Windshield Glass Using Suction Rubber Cup
Courtesy of SUBARU OF AMERICA, INC.
Lightly press the windshield glass for tight fit.
Make flush the adhesive surface jutted out using spatula.
After completion of all work, allow the vehicle to stand for about 24 hours.
NOTE:
- When door is opened/closed after glass is bonded, always lower the door glass first, and then open/close it carefully.
- Move the vehicle slowly.
- For minimum drying time and vehicle standing time before driving after bonding, follow instructions or instruction manual from the adhesive manufacturer.
After curing of adhesive, pour the water on external surface of vehicle to check that there are no water leaks.
NOTE: When a vehicle is returned to the user, tell him or her that the vehicle should not be subjected to heavy impact for at least three days.
Install the cowl panel. < Ref. to INSTALLATION , Cowl Panel. >