Volume 8, Issue 3        May/June  2006

The Cutting Edge
new car installations

2003-2005 Toyota Matrix
by Steve Coyle

1.  GETTING STARTED:
In preparation for the windshield replacement, complete the following steps: 

Begin by meeting with the customer and doing a pre-installation inspection. 

After completing the inspection, protect the interior of the vehicle, and seats. 

Remove the rear view mirror by loosening the Torx screw and sliding the mirror off of the bracket. Next, remove the wiper nut covers and remove the 14 mm wiper nuts from both wipers. 

Remove the push-pin fastener in each corner of the cowl panel. Next, remove the four fasteners in the bulb seal and slide the cowl panel forward. The back edge of the panel hooks under the bottom edge of the glass. Then, remove the three-sided wrap around molding. Start in the bottom corner and pull the molding away from the glass to remove.

2. REMOVING THE ORIGINAL WINDSHIELD:
Using a cold knife or whichever power tool you select, cut the adhesive using caution not to scratch the pinchweld area. The adhesive runs up from the bottom edge of the glass and will require the use of a power cut-out tool. 

 

The long blade works best with the Express tool. The AGRSS Standard requires using the full cut-out method. 

Using a sharp chisel or utility knife, remove the adhesive, leaving a thin skin of well-bonded urethane on the pinchweld. Be careful not to disturb the body paint.

3. PREPARING THE BONDING SURFACES:
Prime the pinchweld according to the adhesive manufacturer’s specifications. Concentrate on any areas of the paint that may have been scratched or damaged during the removal process. The freshly cut urethane bed provides the best bonding surface. Allow proper time for the primers to cure. 

Clean and prime the windshield according to the adhesive manufacturer’s recommendations. Install the moulding onto the glass. 

4. PLACEMENT OF THE NEW WINDSHIELD:
Dry set the windshield into the opening, and adjust for proper alignment. (There are no setting blocks available for this vehicle. The original installation uses setting pins on the top.) Remove the windshield and set it on a cradle with the inboard lite in the upright position. 

Use a properly cut V notch tip to duplicate the original bead size. Apply the adhesive to the glass duplicating the original size and location. Fill the setting pin holes in the pinchweld with adhesive. 

Set the windshield into the opening using the dry set marks. Be careful not to slide the windshield once the adhesive makes contact with the pinchweld.

4. FINISHING TOUCHES:
Reassemble the cowl and wipers. Test the windshield for leaks and then clean the exterior of the glass. Clean and prep the vehicle. 

Steve Coyle is a technical trainer for Performance Achievement Group in Madison, Wis.

REPORTS FROM THE FIELD
Always wear eye, hand and wrist protection while working on the vehicle. Inform the vehicle owner of the cure time and any other additional precautions before installation. Always return the vehicle to manufacturer’s specifications. Protect all interior and exterior portions of the vehicle to prevent any damage.


AGRR
© Copyright 2006 Key Communications Inc. All rights reserved. No reproduction of any type without expressed written permission.