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Windshield Glass: Installation

CAUTION:
  • Before handling the airbag system components, refer to "CAUTION" of "General Description" in "AIRBAG SYSTEM". Ref. to AIRBAG SYSTEM>GENERAL DESCRIPTION>CAUTION .
  • Always use the Subaru genuine windshield glass specially designed for EyeSight. (If the windshield glass other than the glass specially designed for EyeSight is used, the visibility of the camera is blocked or the distortion of the glass prevents the correct measurement of the object, resulting in the EyeSight abnormal operation.)
  • If the damage is found in the glass repair prohibited area, always replace the glass. Damage, dirt, aftermarket part installation or sticker attachment in the prohibited area can affect the recognition of each camera, and thereby the EyeSight and high beam assist functions may not operate properly. Ref. to CAUTION>CHECK WINDSHIELD GLASS INCLUDING PROHIBITED AREA .
  1. Fabricate the cartridge nozzle tip as shown and set the sealant gun with the adhesive.
    G16343634Courtesy of SUBARU OF AMERICA, INC.
    (a) 10 mm (0.39 in)
    (b) 8 mm (0.31 in)
    (c) Sealant gun
  2. 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.
    • Be sure to keep some amount of old adhesive.
    G16343635Courtesy of SUBARU OF AMERICA, INC.
    (a) Adhesive
    (b) Body panel
    (c) 2 mm (0.08 in)
  3. Clean the glass windshield and body.
    CAUTION: Be careful not to damage the glass surface.
    1. Using a scraper, remove adhesive and double-sided tape left on the glass windshield.
    2. Clean the glass windshield and the body with alcohol or appropriate cleaning solvent to completely eliminate cutting powder, dust and dirt.
  4. Install the locating pin. (When reusing the glass)
    1. Using a sponge, apply primer to the locating pin installation position on the glass windshield.

      Preparation items: 

      Glass primer: Dow Automotive ESSEX U-401, U-402 or equivalent

      NOTE:
      • Let primer dry for about one hour before installing the locating pin.
      • Do not touch the surface coated with primer.
    2. Apply adhesive to the locating pin adhesive surface.

      Preparation items: 

      Adhesive: Dow Automotive ESSEX U-400HV or equivalent

    3. Install two locating pins (2 places) to the positions marked with tapes, and remove the tapes.
      CAUTION: Always use new locating pins.
  5. Attach a new dam rubber front to the glass windshield.
    CAUTION: Install the dam rubber front lower along with the dam rubber set mark on the glass side.
    G16441644Courtesy of SUBARU OF AMERICA, INC.
    (a) Locating pin windshield
    (b) Dam rubber front upper
    (c) Dam rubber front side
    (d) Dam rubber set mark
    (e) Dam rubber front lower A
    (f) Dam rubber front lower B
    (g) Seal lower
    (h) 15.3 mm (0.6 in)
    (i) 16.8 mm (0.7 in)
    (j) 3.0 mm (0.1 in) or less
  6. Install a new molding windshield to the glass windshield.
    CAUTION: Be careful to attach the molding windshield so that the molding has no loose or undulating part.
    G13864852Courtesy of SUBARU OF AMERICA, INC.
    1. Using a sponge, apply primer to the molding installation surface in the glass windshield side.

      Preparation items: 

      Glass primer: Dow Automotive ESSEX U-401, U-402 or equivalent

      NOTE:
      • Let primer dry for about ten minutes before installing the molding windshield.
      • Do not touch the surface coated with primer.
    2. Align the molding windshield (A) with both ends of the upper edge (a) of the glass windshield (C).
    3. Install the molding windshield from both corners of the upper edge toward the center (b).
    4. Install the molding windshield from both corners of the upper edge toward the lower side (c).
    5. Firmly apply the double sided tape (B) of the molding windshield evenly to the glass windshield surface.
  7. Attach a new seal upper to the molding windshield.
    G16343639Courtesy of SUBARU OF AMERICA, INC.
    (a) Locating pin windshield
    (b) Dam rubber front upper
    (c) Seal upper
    (d) Molding windshield
    (e) 0+5 mm (0+0.2 in)
    (f) 165 mm (6.5 in)
    (g) Dam rubber front side
    (h) 0+0.5 mm (0+0.02 in)
  8. Install the glass windshield.
    1. Using a sponge, apply primer to the adhesive surfaces of glass windshield side and the body side.
      CAUTION: Do not apply primer to adhesive remaining on the body side.

      Preparation items: 

      Glass primer: Dow Automotive ESSEX U-401, U-402 or equivalent

      Painted surface primer: Dow Automotive ESSEX U-413 or equivalent

      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 windshield.
      • Do not touch the surface coated with primer.
    2. Apply adhesive to the glass windshield end back surface.

      Preparation items: 

      Adhesive: Dow Automotive ESSEX U-400HV or equivalent

      G16441647Courtesy of SUBARU OF AMERICA, INC.
      (a) Application of primer (glass side)
      (b) Application of primer (body side)
      (c) Adhesive
      (d) Molding windshield
      (e) Dam rubber front
      (f) Apply adhesive along to the dam rubber.
      (g) Adhesive application area for the lower part
    3. Fit the locating pin windshield to the vehicle body using suction rubber cups, and install the glass windshield.
      G10319648Courtesy of SUBARU OF AMERICA, INC.
    4. Lightly press the entire perimeter of the glass windshield for tight fit.
    5. Make flush the adhesive surface jutted out using spatula.
  9. After completion of all work, allow the vehicle to stand for about 24 hours.
    NOTE:
    • When opening/closing the door after the glass windshield was bonded, always lower the glass assembly door 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.
  10. Install the sensor assembly rain. (Model with auto wiper) Ref. to GLASS/WINDOWS/MIRRORS>RAIN SENSOR>INSTALLATION .
  11. Install the lens hood (stereo camera and the wide angle mono camera). Ref. to EYESIGHT>LENS HOOD>INSTALLATION .
  12. Install the mirror assembly inner rearview. Ref. to GLASS/WINDOWS/MIRRORS>REARVIEW MIRROR>INSTALLATION .
  13. Install the wide angle mono camera and the cover assembly wide angle mono camera. Ref. to EYESIGHT>WIDE ANGLE MONO CAMERA>INSTALLATION .
  14. Install the stereo camera and cover assembly stereo camera. Ref. to EYESIGHT>STEREO CAMERA>INSTALLATION .
  15. Connect the wiper deicer connector. (Models with wiper deicer)
  16. Install the cowl panel assembly. Ref. to EXTERIOR/INTERIOR TRIM>COWL PANEL>INSTALLATION .
  17. Install the trim panel assembly A pillar. Ref. to EXTERIOR/INTERIOR TRIM>UPPER INNER TRIM>INSTALLATION .
  18. Connect the ground terminal to battery sensor. Ref. to REPAIR CONTENTS>NOTE>BATTERY .
  19. 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.
  20. Perform the initial setting of the sensor assembly rain. Ref. to GLASS/WINDOWS/MIRRORS>RAIN SENSOR>INSPECTION .
  21. Perform the inspection, and adjustment and check of the stereo camera.
  22. Perform the inspection, and adjustment and check of the wide angle mono camera. (Model with wide angle mono camera)
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