Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual - part 1001

10-4  CAB

REMOVAL AND INSTALLATION

For RHD model

For LHD model

Removal Steps

1. Wiper arm assembly
2. Side moulding
3. Vent cowl cover
4. Windshield stopper
5. Upper moulding

V

6. Windshield glass
7. Engine hood rear seal

Installation Steps

V

7. Engine hood rear seal

V

6. Windshield glass

V

5. Upper moulding

V

4. Windshield stopper
3. Vent cowl cover

V

2. Side moulding
1. Wiper arm assembly

CAB  10-5

Important Operation - Removal

6. Windshield Glass
Remove the windshield glass, carefully following the steps
listed below :

1) Use a knife to cut through part of the adhesive caulking

material.

2) Secure one end of a piece of steel piano wire (0.02 inches

in diameter) to a piece of wood that can serve as a handle.

3) Use a pair of needle nose pliers to insert the other end of

the piano wire through the adhesive caulking material at the

edge of the windshield glass.

4) Secure the other end of the piano wire to another piece of

wood.

5) With the aid of an assistant, carefully move the piano wire

with a sawing motion to cut through the adhesive caulking

material around the entire circumferance of the windshield

glass.

6) Lift the windshield from the body.

7) Clean any remaining adhesive caulking material from the

area of the body which holds the windshield.

8) Use a soft rag and unleaded gasoline to wipe off any

adhesive remaining on the windshield glass.

Important Operations - Installation

7. Engine Hood Rear Seal
Install the engine hood rear seal as shown in the illustration.

1

 : Seal

2

 : Clip

3

 : Rear (windshield glass side)

4

 : Front

6. Windshield Glass

1) Clean the windshield glass bonding surface.

2) Use a soft rag and unleaded gasoline to wipe off any

adhesive remaining on the body.

3) Mount the body window glass as shown in the illustration.

Attach spacers at seven (7) locations.

10-6  CAB

4) Apply primer 

1

 #435-95 or equivalent to the body side

bonding surface.  The primer should extend 25 mm (1 in.).

Apply primer #435-40 or equivalent to the windshield glass

side bonding surface.

The primer should extend 15 mm (0.6 in.) from end of the

glass.

Apply the window glass sealing adhesive 

2

.

If you are using an air gun, air pressure should be maintained
at 147 - 294 kpa.

Note :
Open time (1 min. or more) should be set after application
of the primer.

Bonding shall be done within 5 minutes after the sealer
has been applied.

Adjust the setting of the windshield glass with suction discs.

The center of the windshield glass should be in alignment with
the center of the windshield glass opening.

The clearance between body and upper moulding should be
within 0.5 mm (A).

Both of the clearance for RH and LH should be same. (6 mm 

±

2 mm)

Note:
It is a good idea to perform the windshield installation
procedure from beginning to end without pausing.  If you
allow time to elapse between steps, excessive amounts of
adhesive may be extruded from around the windshield.

CAB  10-7

5. Upper Moulding

1) Before installing the windshield moulding (at the upper part

of the windshield), spray hot water at a temperature of

about 140

°

F (60

°

C) onto the windshield glass and the

adhesive.  This will cause curing.

2) Install the upper moulding as soon as hot water has been

applied.  Using a roller push moulding in until it bottoms.

4. Windshield Stopper
Do this immediately after completing the gap adjustment.

2. Side Moulding
Use unleaded gasoline and a soft cloth to wipe away any
excess adhesive.

Cure the bonding at a temperature of 68

°

 - 86

°

F (20

°

 - 30

°

C)

for twenty-four hours.

Check that the windshield does not leak water.