Honda Odyssey Service Manual: Front Corner Glass Replacement

NOTE:

• Wear eye protection while cutting the glass adhesive with a piano wire.

• Put on gloves to protect your hands.

• Use seat covers to avoid damaging any surface.

1. Remove the A-pillar upper/lower trim.

1. Apply protective tape along the edge of the entire front corner glass opening flange.

3. From inside the vehicle, cut through the front corner glass adhesive (A) with a utility knife (B) all the way around.

4. From outside the vehicle, pry the front corner glass clips, then carefully remove the front corner glass assembly (A).

5. Scrape the original adhesive smooth to a thickness of about 2 mm (0.08 in) on the bonding surface around the entire front corner glass opening flange with a putty knife:

   • Do not scrape down to the painted surface of the body; damaged paint will interfere with proper bonding.

   • If any of the clips are broken, remove them from the body.

6. Clean the body bonding surface with a shop towel dampened with isopropyl alcohol. After cleaning, keep oil, grease, and water from getting on the clean surface.

7. If you are reinstalling all of the original front corner glass, scrape off the original adhesive with a putty knife from the front corner glass. Clean the bonding surfaces on the inside face of the front corner glass and the edge of the glass with isopropyl alcohol. Make sure the bonding surface is kept free of water, oil, and grease.

8. Apply a light coat of glass primer to the inside face of the front corner glass (A) as shown, then lightly wipe it off with a gauze or cheesecloth:

   • With the printed dots (B) on the front corner glass as a guide, apply the glass primer to both lower corner area of the front corner glass.

   • Do not apply body primer to the front corner glass, and do not mix up the body and glass primer applicators.

   • Never touch the primed surfaces with your hands. If you do, the adhesive may not bond to the front corner glass properly, causing a leak after the front corner glass is installed.

   • Keep water, dust, and abrasive materials away from primed surfaces.

9. Carefully apply a light coat of body primer to any exposed paint on the front corner glass opening flange. Let the primer dry for at least 10 minutes:

   • Do not apply glass primer to the body, and be careful not to mix up the body and glass primer applicators.

   • Cover on the dashboard before applying the body primer.

   • Never touch the primed surfaces with your hands.

10. Cut a ‘‘V'' in the end of the nozzle (A) on the adhesive cartridge as shown.

11. Put the cartridge in a caulking gun, and run a continuous bead of the adhesive (A) around the front corner glass (B) as shown:

    • With the printed dots (C) on the front corner glass as a guide, apply the adhesive to both side areas of the front corner glass.

    • Apply the adhesive within 30 minutes after applying the glass primer.

    • Make a slightly thicker bead at each corner.

12. Hold the front corner glass (A) with a suction cups over the opening while holding the front corner molding (B) by the other hand. Align the clips, and set the glass down on the adhesive. Lightly push on the front corner glass until its edges are fully seated on the adhesive all the way around.

    NOTE: Do not open or close any of the doors for about an hour until the adhesive is dry.

13. Remove the excess adhesive with a putty knife or a shop towel dampened with isopropyl alcohol.

14. Wait at least an hour for the adhesive to dry, then spray water over the front corner glass, and check for leaks. Mark the leaking areas, let the corner glass dry, then seal with sealant. Let the vehicle stand for at least 4 hours   after front corner glass installation. If the vehicle has to be used within the first 4 hours, it must be driven slowly.

15. Reinstall all 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).