Windshield Glass: Replacement

HINT:

• The installation procedures are the removal procedures in reverse order. However, only installation procedures requiring additional information are included.
• A bolt without a torque specification is shown in the standard bolt chart (see STANDARD BOLT ).

1. REMOVE ROOF HEADLINING ASSY 
   1. Remove the front door opening trim weatherstrip LH and RH.
   2. Remove the front pillar garnish LH and RH.
   3. w/ Rain sensor: Remove the rain sensor.
      1. Pull the stopper downward to release it, as shown in the illustration, and remove the rain sensor.
      2. Disconnect the connector.
         Fig 1: Removing Rain Sensor

         Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   4. Remove the inner rear view mirror together with the center visor.
   5. Remove the map lamp.
   6. Remove the visor LH and RH.
   7. Remove the 2 visor holders.
   8. Remove the assist grip.
   9. Partially remove the roof headlining.

      HINT:

      Do not remove the roof headlining completely. Slightly lower the front section of the roof headlining so that the windshield glass can be removed later in step  8.

2. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSY (see  REPLACEMENT  ) 
   1. Remove the hood to cowl top seal.
   2. Remove the 2 pillar pads No. 4.
   3. Remove the front wiper arm LH and RH.
   4. Remove the cowl top ventilator louver.
3. w/ Water pipe: DISCONNECT WATER PIPE 
   NOTE: When disconnecting the water pipe, be sure to cover the water pipe with a cloth to prevent coolant from spilling onto other parts.
4. REMOVE WINDSHIELD MOULDING OUTSIDE LH 
   1. Using a moulding remover, remove the windshield moulding outside.
5. REMOVE WINDSHIELD MOULDING OUTSIDE RH 

   HINT:

   Use the same procedures described for the LH side.

   Fig 2: Removing Windshield Moulding Outside Using Moulding

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. REMOVE WINDSHIELD MOULDING OUTSIDE CLIP 
   1. Using a drill of less than "OSLASH" 4 mm (0.16 in.), gently and perpendicularly place the drill tip onto the rivet and cut the rivet flanges.

      HINT:

      Wind tape around the drill blade so that the drill blade appears approximately 5 mm (0.20 in.) on the edge.

      NOTE:

      • Be sure to gently place the drill perpendicular to the rivet to prevent the rivet hole and the drill itself from being damaged.
        Fig 3: Cutting Rivet Flanges Using Drill

        Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • Be careful as the cut rivet will be very hot.
   2. Even if the flange is taken off, continue drilling and push cut the remaining fragment with the drill.
   3. Remove the 10 windshield moulding outside clips
7. REMOVE WINDSHIELD MOULDING OUTER UPPER 
   1. Using a knife, cut off the moulding, as shown in the illustration.
      NOTE: Be careful not to damage the vehicle body with the knife.
   2. Remove the remaining moulding.

      HINT:

      Make a partial cut in the moulding. Then pull and remove it by hand.

      Fig 4: Cutting Off Moulding Using Knife

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. REMOVE WINDSHIELD GLASS 
   1. From the interior, insert piano wires between the vehicle body and glass, as shown in the illustration.
   2. Tie objects that can serve as handles (for example, wooden blocks) to all wire ends.
      Fig 5: Inserting Piano Wires Between Vehicle Body And Glass

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      Apply protective tape to the outer surface of the vehicle body to prevent its surface from being scratched.

      NOTE:

      • When separating the glass from the vehicle, be careful not to damage the vehicle's paint or interior / exterior ornaments.
      • To prevent the safety pad from being scratched when removing the glass, place a plastic sheet between the piano wire and safety pad.
        Fig 6: Applying Protective Tape To Outer Surface

        Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. Cut through the adhesive by pulling the piano wire around the glass.
   4. Disengage the stoppers.
   5. Using a suction cup, remove the glass.
      NOTE: Leave as much adhesive on the vehicle body as possible when removing the glass.
9. CLEAN WINDSHIELD GLASS 
   1. Using a scraper, remove the damaged stoppers, dam and adhesive sticking to the glass.
   2. Clean the outer circumference of the glass with white gasoline.
      NOTE:

      • Do not touch the glass surface after cleaning it.
      • Even if using new glass, clean the glass with white gasoline.
        Fig 7: Cleaning Outer Circumference Of Glass With White Gasoline

        Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. CLEAN VEHICLE BODY 
    1. Clean and shape the contact surface of the vehicle body.
       1. Using a knife, cut away any rough adhesive on the contact surface of the vehicle body to ensure the appropriate surface shape.

          HINT:

          Leave as much adhesive on the vehicle body as possible.

          NOTE: Be careful not to damage the vehicle body.
          Fig 8: Roughing Adhesive On Contact Surface Of Vehicle Body Using Knife

          Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
       2. Clean the contact surface of the vehicle body with a piece of shop rag saturated with cleaner.

          HINT:

          Even if all the adhesive has been removed, clean the vehicle body.

11. INSTALL WINDSHIELD GLASS STOPPER NO. 2 
    1. Coat the installation part of the stoppers with Primer G.
       NOTE:

       • Allow the primer coating to dry for 3 minutes or more.
       • Throw away any leftover Primer G.
       • Do not apply too much Primer G.
    2. Install 2 new stoppers onto the glass, as shown in the illustration.

       Specification: 

       MEASUREMENT AREA SPECIFICATIONS
       
       

       Area	Measurement
       A	9.1 mm (0.358 in.)
       B	40.0 mm (1.575 in.)
       C	12.5 mm (0.492 in.)

       Fig 9: Installing Stoppers Onto Glass

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
12. INSTALL WINDSHIELD GLASS STOPPER NO. 1 
    1. Install 2 new stoppers to the vehicle body, as shown in the illustration.
       Fig 10: Installing Stoppers To Vehicle Body

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
13. INSTALL WINDSHIELD GLASS RETAINER 
    1. Install 2 new retainers onto the glass, as shown in the illustration.
       Fig 11: Installing Retainers Onto Glass

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
14. INSTALL WINDOW GLASS ADHESIVE DAM 
    1. Coat the installation part of the windshield glass adhesive dam with Primer G.
       NOTE:

       • Allow the primer coating to dry for 3 minutes or more.
       • Throw away any leftover Primer G.
       • Do not apply too much Primer G.
    2. Install a new dam, applying double-sided tape all the way around the glass except where the stoppers are installed, as shown in the illustration.

       Specification: 

       MEASUREMENT AREA SPECIFICATIONS
       
       

       Area	Measurement
       A	7 mm (0.276 in.)

       Fig 12: Applying Double-Sided Tape All Way Around Glass Except

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
15. INSTALL WINDSHIELD GLASS 
    1. Position the glass.
       1. Using a suction cup, place the glass in the correct position.
       2. Check that the whole contact surface of the glass rim is perfectly even.
       3. Place reference marks between the glass and vehicle body.

          HINT:

          When reusing the glass, check and correct the reference mark positions.

          Fig 13: Placing Glass In Correct Position Using Suction Cup

          Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
          NOTE: Check that the stoppers are attached to the vehicle body correctly.
       4. Remove the glass.
    2. Using a brush, coat the exposed part of the vehicle body with Primer M.
       NOTE:

       • Allow the primer coating to dry for 3 minutes or more.
       • Do not coat the adhesive with Primer M.
       • Throw away any leftover Primer M.
       • Do not apply too much Primer M.
         Fig 14: Coating Exposed Part Of Vehicle Body With Primer M Using Brush

         Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a brush or sponge, coat the edge of the glass and the contact surface with Primer G.

       HINT:

       If an area other than that specified is coated by accident, wipe off the primer with a clean shop rag before it dries.

       NOTE:

       • Allow the primer coating to dry for 3 minutes or more.
       • Throw away any leftover Primer G.
       • Do not apply too much Primer G.
         Fig 15: Coating Edge Of Glass And Contact Surface With Primer G Using Brush Or Sponge

         Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Apply Adhesive.

       Adhesive: Part No. 08850-00801 or equivalent 

       Fig 16: Applying Adhesive (1 Of 2)

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
       Fig 17: Applying Adhesive (2 Of 2)

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
       1. Cut off the tip of the cartridge nozzle, as shown in the illustration.

          HINT:

          After cutting off the tip, use all adhesive within the time described in the table below.

          Usage timeframe: 

          USAGE TIMEFRAME
          
          

          Temperature	Usage Timeframe
          35°C (95°F)	15 minutes
          20°C (68°F)	1 hour 40 minutes
          5°C (41°F)	8 hours

       2. Load the sealer gun with the cartridge.
       3. Coat the glass with adhesive, as shown in the illustration.

          Specification: 

          MEASUREMENT AREA SPECIFICATIONS
          
          

          Area	Measurement
          a	12.5 mm (0.492 in.)
          b	8.0 mm (0.315 in.)
          c	3.0 mm (0.118 in.)

    5. Install the glass to the vehicle body.
       1. Using a suction cup, position the glass so that the reference marks are aligned. Press it in gently along the rim.
          NOTE:

          • Allow the primer coating to dry for 3 minutes or more.
          • Check that the stoppers are attached to the vehicle body correctly.
          • Check that the vehicle body and glass have a small gap between them.
            Fig 18: Pressing It In Gently Along Rim Using Suction Cup

            Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
       2. Lightly press the front surface of the glass to ensure that the glass is securely fit to the vehicle body.
       3. Using a scraper, remove any excess or protruding adhesive.

       HINT:

       Apply adhesive onto the glass rim.

       NOTE: Do not drive the vehicle for the amount of time described in the table below.

       Minimum time: 

       MINIMUM TIME PRIOR TO DRIVING VEHICLE
       
       

       Temperature	Minimum time prior to driving vehicle
       35°C (95°F)	1 hour 30 minutes
       20°C (68°F)	5 hours
       5°C (41°F)	24 hours

       Fig 19: Removing Any Excess Or Protruding Adhesive Using Scraper

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
16. CHECK FOR LEAKS AND REPAIR 
    1. Conduct a leak test after the adhesive has completely hardened.
    2. Seal any leaks with auto glass sealer.
17. INSTALL WINDSHIELD MOULDING OUTER UPPER 
    1. Apply adhesive to the moulding installation area between the glass and the vehicle body.
       Fig 20: Installing Adhesive To Moulding

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Place new moulding onto the vehicle body and tap it by hand.
       Fig 21: Placing Moulding Onto Vehicle Body And Tap It By Hand

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
18. INSTALL WINDSHIELD GLASS SEAL 
    1. Clean the installation area.
    2. Attach new seals, as shown in the illustration.
       Fig 22: Installing Windshield Glass Seal

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
19. INSTALL WINDSHIELD MOULDING OUTSIDE CLIP 
    1. Using an air riveter equipped with a nose piece, strike rivets into the body panel to install the windshield moulding outside clips to the body panel, as shown in the illustration.
       Fig 23: Installing Windshield Moulding Outside Clips To Body Panel Using An Air Riveter Equipped

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
       NOTE: Position the rivets perpendicularly to the surface. Using the riveter on an incorrectly positioned rivet will bend and damage the rivet's mandrel.
       Fig 24: Positioning rivets perpendicularly to surface Using riveter

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
20. INSTALL WINDSHIELD MOULDING OUTSIDE LH 
    1. Install the windshield moulding outside, as shown in the illustration.
21. INSTALL WINDSHIELD MOULDING OUTSIDE RH 
    1. Use the same procedures described for the LH side.
       Fig 25: Installing Windshield Moulding Outside

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
22. w/ Rain sensor: INSTALL RAIN SENSOR 
    1. If reusing the rain sensor: Install new rain sensor tape.
       1. Remove the used rain sensor tape from the windshield glass or rain sensor.
       2. Apply new rain sensor tape on the rain sensor lens surface, indicated by the diagonal lines in the illustration.
          Fig 26: Removing Used Rain Sensor Tape From Windshield Glass Or Rain Sensor

          Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
       NOTE:

       • Keep the tape's exposed adhesive free from dust and fingerprints.
       • Apply the tape exactly according to the measurements. Do not apply tape outside of the specified area.

       Specification: 

       MEASUREMENT AREA SPECIFICATIONS
       
       

       Area	Measurement
       A	10.0 mm (0.394 in.)
       B	11.0 mm (0.433 in.)

    2. Install the rain sensor.
       NOTE:

       • If reusing the windshield glass:

         Make sure that the windshield glass has no residual rain sensor tape from the rain sensor removal process. Remove the tape if necessary.

       • Clean the glass surface with a cloth.
       1. Connect the connector.
       2. Peel the separation paper from the rain sensor tape.
          Fig 27: Installing Rain Sensor

          Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
       3. Securely attach the rain sensor to the bracket.
       4. Push the stopper upward.
23. w/ Water pipe: CONNECT WATER PIPE 
24. w/ Water pipe: REFILL ENGINE COOLANT (see  ENGINE COOLANT  ) 
25. w/ Water pipe: CHECK FOR ENGINE COOLANT LEAKS (see  INSPECTION  )