Subaru Coupes/Sedans/Wagons 1985-1996 Repair Guide

Windshield and Rear Window Glass

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Bonded windshields require special tools and procedures. Due to this fact, removal and installation should be left to a qualified technician if you are unsure of your ability to perform this procedure.


CAUTION
The windshield knife cannot be used on the rear window of the sedan without damaging the surrounding grill. If the grill is not to be damaged, the rear window must be removed by using piano wire.

REMOVAL & INSTALLATION



See Figures 1, 2, 3, 4, 5, 6, 7 and 8



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Fig. Fig. 1: Insert the windshield knife into the adhesive



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Fig. Fig. 2: Cut the adhesive by pulling the knife down with the extension handle



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Fig. Fig. 3: The adhesive can also be cut by using a length of piano wire



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Fig. Fig. 4: Positioning of the fastener and clips-Legacy shown, other models similar



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Fig. Fig. 5: Apply the sealant primer to these points around the windshield



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Fig. Fig. 6: Apply the rubber around these measurements



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Fig. Fig. 7: Position the windshield carefully, aligning the marks made before applying the adhesive



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Fig. Fig. 8: Cut the excess adhesive until it is flush with the glass

You'll need an assistant to complete this job.

  1. Carefully remove the wiper arms and windshield molding.
  2.  
  3. Put protective tape on the body to prevent damage.
  4.  
  5. Apply soapy water to the surface of the adhesive agent so the knife blade slides smoothly.
  6.  
  7. Cut off excess adhesive agent.
  8.  
  9. Remove stoppers and spacers from glass.
  10.  
  11. Put the windshield knife into layer of adhesive.
  12.  
  13. Hold windshield knife in one hand and cut adhesive by pulling putty knife parallel to the glass while holding knife edge at a right angle. Make sure that the knife stays along the surface of the glass.
  14.  

When first putting knife into layer of adhesive, select a point with a wide gap between the body and glass.

  1. Working from the inside of the car, apply even pressure to the windshield and push it outward, while an assistant removes it from the car.
  2.  

To install:
  1. After cutting layer of adhesive, remove the dam rubber left on the body.
  2.  
  3. Remove the remaining space stopper. At this time, also remove two-sided tape from spacer stopper completely.
  4.  
  5. Using a cutting knife, cut layer of adhesive sticking to the body and finish it into a smooth surface of about 2mm in thickness.
  6.  
  7. Thoroughly remove chips dirt and dust from the body surface.
  8.  
  9. Clean the body wall surface and the upper surface of the layer of adhesive with a solvent such as alcohol or white gasoline.
  10.  


CAUTION
Never smoke or have any form of an open flame nearby when using alcohol or gasoline, as it is extremely flammable.

  1. Place new spacer stoppers into positions from which the old ones where removed. Remove the tack paper from the back of the spacer stopper and stick it to the body firmly.
  2.  
  3. Place the windshield onto the body and adjust the position of the glass so that the gap between the body and glass is uniform on all sides.
  4.  
  5. Match mark the body and glass in several places.
  6.  
  7. Remove the glass from the body and clean the surface of glass to be adhered with alcohol or white gasoline.
  8.  
  9. Using a sponge, apply primer to the part of the glass and the part of the body to be adhered.
  10.  
  11. Allow the primer to dry for about 10 minutes before proceeding to the next step.
  12.  


WARNING
Cover all surfaces that primer may come into contact with, as it is very hard to remove.


CAUTION
Do not touch primer coated surface under any circumstances.

  1. Cut the nozzle tip of the adhesive cartridge to a 45 degree angle, open the cartridge, attach the nozzle and place it into the gun.
  2.  
  3. Apply the adhesive uniformly to all sides of adhesion surface while operating gun along the face of the glass edge. Adhesive build up should be 0.47-0.59 in. (12-15mm) from the glass surface.
  4.  
  5. With the help of an assistant, place the glass onto the body and align the match marks. Press the glass firmly into position, then add adhesive where needed.
  6.  
  7. Install the upper windshield molding and remove the excess adhesive with a spatula. Then clean with alcohol.
  8.  

After the molding has been installed, do not open the doors or move the car unless it is absolutely necessary. If the doors must be opened, lower the windows, and open and close the doors very gently. After one hour the car can be tested for water leakage.

  1. Install the front lower molding, front pillar cover, wiper wheel assembly and wiper arm assembly.
  2.  

When testing for water leakage, do not squirt a strong hose stream on the vehicle. If the vehicle must be moved, do so gently, sudden shock could cause the windshield to shift.

  1. After completing all operations, leave the vehicle alone for 24 hours. After 24 hours the vehicle may be driven, but should not be subjected to heavy shock for at least three days.
  2.  

 
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