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Glass: Removal & Installation Honda Pilot II

Windows 38 illustrations ~2903 words

Windshield Replacement

Note. Put on gloves to protect your hands. Wear eye protection while cutting the glass adhesive with a piano wire. Use seat covers to avoid damaging the seats. Glass adhesive can be efficiently cut with a commercially available auto glass tool. See the tool manufacturer's instructions for details.

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Scheme 3: Windshield Replacement
Scheme 3: Windshield Replacement

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  1. Remove these items: Cowl cover (see «COWL COVER REPLACEMENT»(ref-333593-S23280153962009072100000) ) Rearview mirror See «REARVIEW MIRROR REPLACEMENT»(ref-333582-S42513324382009072100000) See «WITH AUTOMATIC DIMMING MIRROR»(ref-333582-S26755337942009072100000) See «WITH REARVIEW MONITOR»(ref-333582-S02230449542009072100000) A-pillar trim, both sides (see «TRIM REMOVAL/INSTALLATION - PILLAR AREAS»(ref-333585-S08240123312009072100000) ) Roof moldings, both sides (see «ROOF MOLDING REPLACEMENT»(ref-333593-S10589678212009072100000) ) Windshield side trims (see «WINDSHIELD SIDE TRIM REPLACEMENT»(ref-333593-S08645781102009072100000) )
  2. Remove the molding (A) from the upper edge of the windshield (B). If necessary, cut the molding with a utility knife.
  3. If the old windshield is reinstalled, make alignment marks (A) across the glass and body with a grease pencil.
  4. Pull down the front portion of the headliner (see «HEADLINER REMOVAL/INSTALLATION»(ref-333585-S23723750292009072100000) ). Do not bend the headliner excessively, or you may crease or break it.
  5. Apply protective tape along the edge of the dashboard and body. Use an awl to punch a hole at an inside upper corner of the windshield through the rubber dam, adhesive, and the windshield upper seal. Push a piece of piano wire through the hole, and wrap each end around a piece of wood.
  6. With a helper on the outside, pull the piano wire (A) back and forth in a sawing motion. Hold the piano wire as close to the windshield (B) as possible to prevent damage to the body and dashboard. Carefully cut through the rubber dam and adhesive (C) around the entire windshield. Cutting positions
  7. Carefully remove the windshield.
  8. Scrape smooth the old adhesive with a knife until there is a thickness of about 2 mm (0.08 in.) on the bonding surface around the entire windshield opening flange: Do not scrape down to the painted surface of the body; damaged paint will interfere with proper bonding. Remove the rubber dam and fasteners from the body.
  9. Clean the body bonding surface with a sponge dampened in isopropyl alcohol. After cleaning, keep oil, grease and water from getting on the clean surface.
  10. If you are installing the old windshield, scrape old adhesive, the clips, the rubber dam, from the windshield with a putty knife. Clean the bonding surfaces on the inside face and the edge of the surfaces on the inside face and the edge of the windshield with isopropyl alcohol. Make sure the bonding surface is kept free of water, oil, and grease.
  11. Attach the rubber dams A, B and the upper clips (C) with adhesive tape to the inside face of the windshield (D) as shown: Be sure the rubber dams and upper clips line up with the alignment marks (E). Be careful not to touch the windshield where adhesive will be applied.
  12. Attach the dashboard seal (A) with adhesive tape to the inside surface of the windshield (B) as shown below.
  13. Attach the molding (A) with adhesive tape (B) to the upper edge of the windshield (C). Be careful not to touch the windshield where the adhesive will be applied.
  14. Attach the molding upper seal (A) with adhesive tape to the inside surface of the molding (B) as shown below.
  15. Set the windshield in the opening, and center it. Make alignment marks (A) across the windshield and body with a grease pencil at the four points shown. Make sure both clips (B) contact with the edge of the body holes. Be careful not to touch the windshield where the adhesive will be applied.
  16. Remove the windshield.
  17. With a sponge, apply a light coat of glass primer around the edge of the windshield (A) between the dams (B, C) and molding (D) as shown below, then lightly wipe it off with gauze or cheesecloth: Apply glass primer to the molding. Do not apply body primer to the windshield, and do not get body and glass primer sponges mixed up. Never touch the primed surfaces with your hands. If you do, the adhesive may not bond to the windshield properly, causing a leak after the windshield is installed. Keep water, dust, and abrasive materials away from primed surfaces.
  18. With a sponge carefully apply a light coat of body primer to any exposed paint or metal around the flange where new adhesive will be applied. Let the primer dry for at least 10 minutes: Do not apply body primer to any remaining original adhesive on the flange. Be careful not to mix up the body and glass primer sponges. Never touch the primed surfaces with your hands.
  19. Cut a "V" in the end of the nozzle (A) on the adhesive cartridge as shown below.
  20. Put the cartridge in a caulking gun, and run a continuous bead of adhesive (A) around the edge of the windshield (B) between the dam (C) and the molding (D) as shown below. Apply the adhesive within 30 minutes after applying the glass primer. Make a slightly thicker bead at each corner.
  21. Hold the windshield with suction cups to over the opening, align it with the alignment marks made in step 15, and set it down on the adhesive. Lightly push on the windshield until its edges are fully seated on the adhesive all the way around. NOTE: Do not open or close the doors for about an hour until the adhesive is dry.
  22. Remove the excessive adhesive with a putty knife or a shop towel dampened with isopropyl alcohol.
  23. Wait at least an hour for the adhesive to dry, then spray water over the windshield and check for leaks. Mark leaking areas, and let the windshield dry, then seal with sealant. Let the vehicle stand for at least 4 hours after windshield installation. If the vehicle has to be used with the first 4 hours, it must be driven slowly.
  24. Reinstall all remaining removed parts. NOTE: Advise the customer not to do the following things for 2 to 3 days: Slam the doors with all the windows rolled up. Twist the body excessively (such as when going in and out of driveways at an angle or driving over rough, uneven roads).

Note. Put on gloves to protect your hands. Wear eye protection when removing the glass with piano wire. Use seat covers to avoid damaging any surface. Do not damage the glass antenna grid lines and terminals.

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Scheme 16: Quarter Glass Replacement
Scheme 16: Quarter Glass Replacement

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  1. Remove these items: See «C-PILLAR TRIM»(ref-333585-S12168036682009072100000) See «D-PILLAR TRIM»(ref-333585-S33408886062009072100000) See «UPPER QUARTER WINDOW TRIM»(ref-333585-S38230762532009072100000)
  2. Passenger's side: Disconnect the glass antenna connector (A).
  3. If the old quarter glass is reinstalled, make alignment marks across the glass and body with a grease pencil.
  4. Apply protective tape along the inside and outside edges of the body. Make a hole through the adhesive with an awl, from inside the vehicle. Push a piece of piano wire through the hole, and wrap each end around a piece of wood.
  5. With a helper on the outside, pull the piano wire (A) back and forth in a sawing motion. Hold the piano wire as close to the quarter glass (B) as possible to prevent damage to the body, and carefully cut through the adhesive (C) around the entire quarter glass. Cutting positions
  6. Carefully remove the quarter glass.
  7. If the old quarter glass is reinstalled, make the alignment marks (A) along the edges of the clips (B) with a grease pencil as shown.
  8. Scrape smooth the old adhesive with a knife until there is thickness of about 2 mm (0.08 in.) on the bonding surface around the entire quarter glass opening flange: Do not scrape down to the painted surface of the body; damaged paint interferes with proper bonding. Remove the clips from the body.
  9. Clean the body bonding surface with a sponge dampened in isopropyl alcohol. After cleaning, keep oil, grease, and water from getting on the surface.
  10. If you are reinstalling the old glass, scrape off all the old adhesive with a putty knife and the damaged clips from the quarter glass. Clean the bonding surfaces on the inside face and the edge of the quarter glass with isopropyl alcohol. Make sure the bonding surface is kept free of water, oil and grease.
  11. Attach the rubber dam (A) with adhesive tape to the inside surface of the glass (B) as shown: Be sure both ends of the rubber dam line up with the alignment marks (C). Be careful not to touch the glass where the adhesive is applied.
  12. Attach the clips (A) with adhesive tape to the inside face of the quarter glass (B) as shown. Be sure the clips line up with the alignment marks (C) you made in step 7. Be careful not to touch the quarter glass where the adhesive is applied.
  13. With a sponge, apply a light coat of glass primer to the edge of the glass (A) and along the rubber dam (B) as shown, then lightly wipe it off with gauze or cheesecloth: With the printed dots (C) on the quarter glass as a guide, apply the glass primer to the corner portions of the quarter glass. Do not apply body primer to the quarter glass, and do not get body and glass primer sponges mixed up. Never touch the primed surfaces with your hands. If you do, the adhesive may not bond to the quarter glass properly, causing a leak after the quarter glass is installed. Keep water, dust, and abrasive materials away from primed surfaces.
  14. With a sponge, carefully apply a light coat of body primer to any exposed paint or metal around the flange where new adhesive will be applied. Let the primer dry for at least 10 minutes: Do not apply body primer to any remaining original adhesive on the flange. Be careful not to mix up the body and glass primer sponges. Never touch the primed surfaces with your hands.
  15. Cut a "V" in the end of the nozzle (A) on the adhesive cartridge as shown.
  16. Put the cartridge in a caulking gun, and run a continuous bead of adhesive (A) around the edge of the glass (B) as shown. With the glass primer (C) you applied in step 13 on the quarter glass as a guide, apply adhesive to the corner portions of the quarter glass. Apply the adhesive within 30 minutes after applying the glass primer. Make a slightly thicker bead at each corner.
  17. Hold the quarter glass (A) over the opening, align it, and set it with suction cups (B) down on the adhesive. Lightly push on the quarter glass until its edges are fully seated on the adhesive all the way around. NOTE: Do not open or close the doors for an hour until the adhesive is dry.
  18. Remove the excess adhesive with a putty knife or a shop towel dampened with isopropyl alcohol.
  19. Wait at least an hour for the adhesive to dry, then spray water over the quarter glass and check for leaks. Mark the leaking areas, let the quarter glass dry, then seal wit sealant. Let the vehicle stand for at least 4 hours after quarter glass installation. If the vehicle has to be used with the first 4 hours, it must be driven slowly.
  20. Reinstall all remaining removed parts. NOTE: Advise the customer not to do the following things for 2 to 3 days: Slam the doors with all the windows rolled up. Twist the body excessively (such as when going in and out of driveways at an angle or driving over rough, uneven roads).

Note. Put on gloves to protect your hands. Take care not to scratch the tailgate. When prying with a flat-tipped screwdriver, wrap it with protective tape to prevent damage. Do not damage the rear window defogger grid lines or terminals. Use eye protection when prying the support strut clips.

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Scheme 27: Hatch Glass/Hatch Glass Support Strut Replacement
Scheme 27: Hatch Glass/Hatch Glass Support Strut Replacement

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  1. Remove the tailgate spoiler trim from the body (see «TAILGATE HINGE COVER REPLACEMENT»(ref-333593-S02892657622009072100000) ).
  2. Release the tabs (A), then remove the terminal covers (B) from both sides. Detach the clips (C) and disconnect the rear window defogger connectors (D) from both sides.
  3. With the help of an assistant, use a flat-tip screwdriver (A) to pry the support strut clips (B) from each end of the support strut (C) at the hatch glass and tailgate, then release the support strut from the pivot bolts (D). Do not remove the clips from the support strut.
  4. With an assistant holding the hatch glass, remove the pivot bolt (A).
  5. With an assistant holding the hatch glass, remove the bolts. Unlock the hatch glass latch.
  6. Remove the hatch glass (A). Take care not to scratch the tailgate.
  7. Install the glass and support struts in the reverse order of removal, and note these items: Make sure the rear window defogger connectors are plugged in properly. Adjust the position of the glass (see «HATCH GLASS ADJUSTMENT»(ref-333583-S13363226822009072100000) ). Check that the hatch glass opens properly and locks securely. Apply medium strength liquid thread lock to the pivot bolt before installation.
  8. Check for water leaks (see step 9 on «REAR WINDOW MOLDING REPLACEMENT»(ref-333583-S14235951642009072100000) ) and wind noise.

Note. Put on gloves to protect your hands. Place the hatch glass on a padded surface to prevent damage. Do not damage the rear window defogger grid lines or terminals. Remove the bolts with a T30 Torx bit.

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Scheme 32: Hatch Glass Disassembly/Reassembly
Scheme 32: Hatch Glass Disassembly/Reassembly

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Scheme 33: Hatch Glass Adjustment
Scheme 33: Hatch Glass Adjustment

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  1. Remove the tailgate lower trim panel (see «TRIM REMOVAL/INSTALLATION - TAILGATE AREA»(ref-333585-S04198044782009072100000) ).
  2. With the help of an assistant, remove the hatch glass support struts from both sides (see «HATCH GLASS/HATCH GLASS SUPPORT STRUT REPLACEMENT»(ref-333583-S01379884392009072100000) ). Hold the hatch glass when opening and closing it.
  3. Slightly loosen each bolt and screw.
  4. Adjust the hatch glass (A) alignment in the following sequence: Adjust the hatch glass latch (B) forward and rearward to make the hatch glass fit flush with the tailgate at the bottom edge. There should be no gap between the hatch glass stops (C) and hatch glass on each side. Adjust the striker (D) right and left until it's centered in the hatch glass latch.
  5. Tighten each bolt and screw securely.
  6. Check that the hatch glass opens properly and locks securely.
  7. Reinstall the support struts securely (see «HATCH GLASS/HATCH GLASS SUPPORT STRUT REPLACEMENT»(ref-333583-S01379884392009072100000) ).
  8. Reinstall the tailgate lower trim panel (see «TRIM REMOVAL/INSTALLATION - TAILGATE AREA»(ref-333585-S04198044782009072100000) ).
  9. Check for water leaks. Run water over the roof and on the sealing area as shown below, and note these items: Use a 12 mm (1/2 in.) diameter hose (A). Adjust the rate of water flow as shown below (B). Do not use a nozzle. Hold the hose about 300 mm (12 in.) away from the tailgate (C).

Rear Window Molding Replacement

Note. Put on gloves to protect your hands. Place the hatch glass on a padded surface to prevent damage. Do not damage the rear window defogger grid lines and terminals.

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Scheme 35: Rear Window Molding Replacement
Scheme 35: Rear Window Molding Replacement

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  1. Remove the hatch glass (see «HATCH GLASS/HATCH GLASS SUPPORT STRUT REPLACEMENT»(ref-333583-S01379884392009072100000) ).
  2. Remove the molding (A) from the upper edge of the hatch glass (B). If necessary, cut the molding with a utility knife.
  3. Use a putty knife to scrape off all of the adhesive from the hatch glass. Clean the upper edge of the hatch glass with isopropyl alcohol where the new molding will be installed. After cleaning, keep oil, grease, and water from getting on the surface.
  4. Apply primer to the upper edge of the hatch glass (A). Be careful not to touch the hatch glass where the primer will be applied.
  5. Apply primer to the entire groove of the molding (A), and run a bead of urethane adhesive (B) in the groove of the molding.
  6. Align the edge of the molding (A) with the corner edge of the hatch glass (B), and attach the molding.
  7. Scrape or wipe the excess adhesive off with a putty knife or towel. To remove adhesive from the hatch glass, wipe with a soft shop towel dampened with alcohol.
  8. Let the adhesive dry for at least 1 hour.
  9. Reinstall the hatch glass.
  10. Adjust the hatch glass (see «HATCH GLASS ADJUSTMENT»(ref-333583-S13363226822009072100000) ).
  11. Check for water leaks around the tailgate (see step 9 on «REAR WINDOW MOLDING REPLACEMENT»(ref-333583-S14235951642009072100000) ).

Note. Put on gloves to protect your hands. Take care not to scratch the tailgate.

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Scheme 39: Hatch Glass Weatherstrip Replacement
Scheme 39: Hatch Glass Weatherstrip Replacement

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  1. Remove the tailgate side trim from both sides (see «TRIM REMOVAL/INSTALLATION - TAILGATE AREA»(ref-333585-S04198044782009072100000) ).
  2. Disconnect the rear window defogger connectors from both sides (see step 2 on «HATCH GLASS/HATCH GLASS SUPPORT STRUT REPLACEMENT»(ref-333583-S01379884392009072100000) ).
  3. Remove the hatch glass weatherstrip (A) by pulling it out.
  4. Clean the bonding surface around the hatch glass opening flange with isopropyl alcohol.
  5. Apply sealant (SUNRISE MEISEI B-33C, or equivalent) (A) in the groove around the hatch glass weatherstrip (B).
  6. Locate the painted alignment mark (C) on the hatch glass weatherstrip. Align the painted mark with the alignment notch in the center of the hatch glass opening, and install the weatherstrip. Make sure it's seated completely and facing in the direction shown. Make sure there are no wrinkles in the weatherstrip.
  7. Check for water leaks (see step 9 on «REAR WINDOW MOLDING REPLACEMENT»(ref-333583-S14235951642009072100000) ).

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