Windshield Glass: Replacement

WARNING: This page is about a different car, the 2005 Toyota Sienna. However, it is still accessible from the selected car via links, so may be relevant.

HINT:

The installation is in the reverse order of the removal. However, when there is a special point concerning the installation, it is indicated.

REMOVE ROOF HEADLINING ASSY (See REPLACEMENT )
1. Remove the front door weatherstrip LH.
2. Remove the front door weatherstrip RH.
3. Remove the front pillar garnish LH.
4. Remove the front pillar garnish RH.
5. Remove the LH visor.
6. Remove the RH visor.
7. Remove the assist grip.
8. Remove the roof console box.
9. Remove the 2 visor holders.
10. Remove the roof console box assy.
11. w/ Sliding roof:
  Remove the sun roof opening trim molding.
12. Remove the roof headlining assy.
REMOVE INNER REAR VIEW MIRROR ASSY (See INSPECTION )
REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSY (See WINDSHIELD WIPER MOTOR ASSY )
1. Remove the 2 front wiper arm head caps.
2. Remove the FR wiper arm LH.
3. Remove the FR wiper arm RH.
4. Remove the front fender to cowl side seal LH.
5. Remove the front fender to cowl side seal RH.
6. Remove the cowl top ventilator louver.
REMOVE WINDSHIELD MOLDING OUTER UPPER
1. Using a knife, cut off the molding as shown in Fig 1.
  NOTE: Do not damage the body with the knife.
  
  Fig 1: Cutting Off Molding
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the remaining molding.
  When removing, make a partial cut, then pull and remove it by hand.
3. w/ Deicer:
  Disconnect the connector as shown in Fig 2.
  
  Fig 2: Disconnecting Connector (W/Deicer)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE WINDSHIELD GLASS
1. Pass a piano wire between the vehicle body and glass from the interior.
  
  Fig 3: Passing Piano Wire Between Vehicle Body & Glass From Interior
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Tie both wire ends to wooden blocks or similar objects.
  HINT:
  
  Apply protective tape to the outer surface to prevent the surface from being scratched.
  NOTE:
  - When separating the glass, take care not to damage the paint and the interior and 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 4: Applying Protective Tape To Outer Surface
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Cut off the adhesive by pulling piano wire around the glass.
4. Disengage the stoppers.
5. Using a suction cup, remove the glass.
NOTE: Leave as much adhesive on the body as possible when removing the glass.
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.

Fig 5: Cleaning Windshield Glass
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL WINDSHIELD GLASS STOPPER NO. 2
1. Coat the installation part of the stopper with Primer G.
  NOTE:
  - Allow the primer coating to dry for 3 minutes or more.
  - Do not keep any of the opened Primer G for later use.
  - Do not apply too much primer.
2. Install 2 new stoppers onto the glass as shown in Fig 6.
Fig 6: Installing Stoppers Onto Glass
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Dimension:
WINDSHIELD GLASS STOPPER NO. 2

A 40.0 mm (1.575 in.)

B 7.7 mm (0.303 in.)
INSTALL WINDSHIELD GLASS STOPPER NO. 1
1. Install 2 new stoppers to the vehicle body as shown in Fig 7.
Fig 7: Installing Stoppers To Vehicle Body
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL DAM, WINDOW GLASS ADHESIVE

Coat the installation part of the window glass adhesive dam with Primer G.
NOTE:
- Allow the primer coating to dry for 3 minutes or more.
- Do not apply too much primer.
Install a new dam, applying double-sided tape all the way around the glass except where the dam is installed as shown in Fig 8.

Fig 8: Installing Dam, Window Glass Adhesive

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Dimension:

DAM, WINDOW GLASS ADHESIVE

a	7.0 mm (0.276 in.)
b	6.0 mm (0.236 in.)
c	35.0 mm (1.378 in.)

INSTALL WINDSHIELD MOLDING OUTER UPPER
1. Using a brush or sponge, coat the edge of the glass and the contact surface with Primer G.
  NOTE:
  - Allow the primer coating to dry for 3 minutes or more.
  - Do not coat the adhesive with Primer G.
  - Do not keep any of the opened Primer G for later use.
2. Install the molding.

INSTALL WINDSHIELD GLASS

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.
  Leave as much adhesive on the vehicle body as possible.
  
  Fig 9: Cutting Rough Adhesive On Contact Surface
  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.
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.
  NOTE: Check that the stoppers are attached to the vehicle body correctly.
  
  When reusing the glass, check and correct the reference mark positions.
4. Remove the glass.
Fig 10: Positioning Glass
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
- Do not keep any of the opened Primer M for later use.
Fig 11: Coating Exposed Part Of Vehicle Body With Primer M
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.

Fig 12: Coating Edge Of Glass And Contact Surface With Primer G
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
NOTE:
- Allow the primer coating to dry for 3 minutes or more.
- Do not keep any of the opened Primer G for later use.

Apply adhesive.

Adhesive: Part No. 08850-00801 or equivalent

Cut off the tip of the cartridge nozzle as shown in Fig 13.

Fig 13: Cutting Off Tip Of Cartridge Nozzle

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

After cutting off the tip, use all adhesive within the time described in TACKFREE TIME .

TACKFREE TIME

Temperature	Tackfree Time
35°C (95°F)	15 minutes
20°C (68°F)	100 minutes
5°C (41°F)	8 hours

Load the sealer gun with the cartridge.
Coat the glass with adhesive as shown in Fig 13.

Dimension:

WINDOW GLASS DIMENSION

a	12.0 mm (0.472 in.)
b	8.0 mm (0.315 in.)
c	3.0 mm (0.118 in.)
d	40.0 mm (1.575 in.)

Install the glass.
1. Using a suction cup, position the glass so that the reference marks are aligned, and press it in gently along the rim.
  
  Fig 14: Positioning Glass Using Suction Cup
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Allow the primer coating to dry for 3 minutes or more.
  - Check that the stoppers are attached to the vehicle body correctly.
  - Check the clearance between the vehicle body and glass.
2. Lightly press the front surface of the glass to ensure a close fit.
3. Using a scraper, remove any excess or protruding adhesive.

Fig 15: Removing Excess Or Protruding Adhesive

Apply adhesive onto the glass rim.

NOTE: Take care not to drive the vehicle for the time described in TEMPERATURE REFERENCE .

Minimum time:

TEMPERATURE REFERENCE

Temperature	Minimum time prior to driving vehicle
35°C (95°F)	1.5 hours
20°C (68°F)	5 hours
5°C (41°F)	24 hours

Fig 16: Applying Adhesive Onto Glass Rim

INSPECT FOR LEAKS AND REPAIR
1. Conduct a leak test after the adhesive has completely hardened.
2. Seal any leaks with auto glass sealer.