The Cutting Edge
new car installations
2011 Subaru Forester
by Jamie Browning
1. Getting Started:
For vehicle and glass preparations please refer to AGRSS/ANSI 002-2002
as well as your adhesive manufacturer’s recommendations. Inspect the windshield
for defects and any contamination that might compromise the bonding of
the adhesive. Also look for any distortion, scratches or defects on the
glass or moulding.1
First, remove the rear view mirror by turning the base clockwise or counterclockwise
in a 90-degree motion. According to Subaru’s service procedures, the horseshoe-shaped
spring located in the mirror bracket should be replaced upon removal.
To remove the A-pillar covers (if required) use a panel tool to release
the securing clips on each side. Move to the exterior of the vehicle and
remove the wiper arms by removing the two black caps covering the wiper
nuts. Next, remove the wiper nuts and use a wiper arm-puller to safely
remove the wiper arms; note the driver and passenger side. To remove the
cowl panel (plenum chamber cover), detach the five tabs for each side
and remover the corner sections. Next, unplug the wiper-washer hose, being
careful not to damage the connector. Remove the two clips securing the
left and right side, and also the five push pins along the front edge,
and remove the cowl from the vehicle. Unplug the pigtail for the heated
wiper park area if equipped and remove the molding from around the sides
and top, and you are now ready to begin the cut-out process.
For the sides and top of the windshield, a cold knife or power tool can
be used as well as a wire. For the bottom, a power tool or wire can be
used. Keep in mind that there is no one correct method of removal. The
technician should use the tool with which he feels most comfortable and
the one that achieves a safe removal both for the vehicle and the technician.
Trim the existing urethane bead, leaving it 1 to 2 millimeters (mm) in
height. Use your adhesive manufacturer’s pinchweld primer to prime all
scratches, if any, and allow for proper drying according to your adhesive
manufacturer’s recommendations. Please note that only the full-cut method
is permitted by the AGRSS/ANSI 002-2002 Standard.
Dry-fit the new windshield and mark it properly to ensure the correct
setting procedure. Prepare the windshield according to your adhesive manufacturer’s
recommendations, and then apply the adhesive and install the windshield.
Subaru recommends using a tip for the urethane that is cut at a 60-degree
angle and is 10-mm wide and 8-mm tall. Make sure the deck height is correct
and the markings on the windshield line up with those on the body that
were applied during the dry set
5. Finishing Touches:
Install the cowl, wipers and mirror in reverse order from removal and
torque the wiper nuts to 22Nm or 16-foot pounds. Be sure to check the
heating element if equipped and wiper operation before returning the vehicle
to the owner. Check for any leaks and be sure to inform the vehicle owner
of the safe drive-away time. Also be sure to record all lot numbers from
the adhesive, VIN number, and primers as well as the DOT number from the
Jamie Browning was the gold medalist in the 2009 Pilkington Classic
Auto Glass Technician Olympics. He has more than 17 years’ experience
in the AGRR industry.
1Make sure to note if
the windshield being replaced is heated in the wiper park area before
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