Volume 14, Issue 2 - March/April 2012

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.

2. Removal:
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.

3. Preparation:
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.

4. Placement:
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 windshield.

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 removal.

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