Windshield glass: Removal

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.
Removal of the wiper arm head caps (Refer to Removal )
Removal of the front wiper arm & blade ASSY LH (Refer to Removal )
Removal of the front wiper arm & blade ASSY RH (Refer to Removal )
Removal of front fender to cowl side seal LH (Refer to Installation )
Removal of the front fender to cowl side seal RH
NOTE: Remove the part in the same manner as LH side.
Removal of the cowl ventilator louver (Refer to Installation )
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 Disassembly )
CAUTION: Be careful not to damage the roof head lining ASSY.
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.
  
  Fig 1: Applying Protective Tape To Body Side Of Circumference Of Windshield Glass
  Courtesy of SUBARU OF AMERICA, INC.
2. Using the cutter knife, cut the windshield outside molding.
  CAUTION:
  - 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.
  Fig 2: Cutting Windshield Outside Molding
  Courtesy of SUBARU OF AMERICA, INC.
3. When the windshield glass is reused.
  
  Fig 3: Identifying Alignment Marks On Windshield Glass
  Courtesy of SUBARU OF AMERICA, INC.
  1. 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
  1. Apply sufficient amount of soapy water to the adhesive section.
  2. Insert the windshield knife into the adhesive section.
  3. 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.
  CAUTION:
  - Never twist the windshield glass knife.
  - Do not damage the windshield glass.
  NOTE: Begin from where the windshield glass and the body is most distant.
  
  Fig 4: Inserting Windshield Knife Into Adhesive Section
  Courtesy of SUBARU OF AMERICA, INC.
6. When using piano wire
  1. Using an air drill, make a hole in the adhesive section and pass the piano wire through the hole.
  2. 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.
  3. Pull the piano wire both ways and cut the adhesive on the windshield glass.
  CAUTION:
  - 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.
  Fig 5: Identifying Piano Wire And Windshield Glass Stopper
  Courtesy of SUBARU OF AMERICA, INC.
7. Holding the suction rubbers, release the 2 tabs of the windshield glass stopper, then remove the windshield glass.
  CAUTION:
  - 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.
  Fig 6: Identifying Windshield Glass Stopper
  Courtesy of SUBARU OF AMERICA, INC.
Removal of window glass adhesive dam
1. When the windshield glass is reused.
  1. Using the scraper, remove the window glass adhesive dam.
    CAUTION:
    Do not damage the windshield glass.
    
    The window glass adhesive dam must be replaced by a new one.
    Fig 7: Identifying Window Glass Adhesive Dam
    Courtesy of SUBARU OF AMERICA, INC.
Removal of windshield glass seal
1. When the windshield glass is reused.
  1. Using the scraper, remove 2 window glass seals.
    CAUTION:
    Do not damage the windshield glass.
    
    Windshield glass seal must be replaced by a new one.
Fig 8: Identifying Windshield Glass Seal
Courtesy of SUBARU OF AMERICA, INC.
Removal of windshield outside molding
1. When the windshield glass is reused.
  1. Using the scraper, remove the windshield outside molding.
    CAUTION:
    Do not damage the windshield glass.
    
    Windshield outside molding must be replaced by a new one.
Fig 9: Identifying Windshield Outside Molding
Courtesy of SUBARU OF AMERICA, INC.