Windshield Glass: Replacement

HINT:

The installation procedures are the removal procedures in reverse order. However, only installation procedures requiring additional information are included.

REMOVE FR WIPER ARM & BLADE ASSY LH (SEE REPLACEMENT )
REMOVE FR WIPER ARM & BLADE ASSY RH (SEE REPLACEMENT )
REMOVE COWL TOP VENTILATOR LOUVER RH (SEE REPLACEMENT )
REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP LH (SEE REPLACEMENT )
REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP RH (SEE REPLACEMENT )
REMOVE FRONT PILLAR GARNISH LH (SEE REPLACEMENT )
REMOVE FRONT PILLAR GARNISH RH (SEE REPLACEMENT )
REMOVE ASSIST GRIP SUB-ASSY FRONT (SEE REPLACEMENT )
REMOVE ASSIST GRIP SUB-ASSY (SEE REPLACEMENT )
REMOVE VISOR BRACKET COVER (SEE REPLACEMENT )
REMOVE LH VISOR ASSY (SEE REPLACEMENT )
REMOVE RH VISOR ASSY (SEE REPLACEMENT )
REMOVE ROOF CONSOLE BOX ASSY (SEE REPLACEMENT )
REMOVE VISOR HOLDER (SEE REPLACEMENT )
REMOVE INNER REAR VIEW MIRROR STAY HOLDER COVER (w/GARAGE DOOR OPENER) (SEE REPLACEMENT )
REMOVE RAIN SENSOR COVER (w/AUTO WIPER) (SEE REPLACEMENT )
REMOVE RAIN SENSOR (w/AUTO WIPER) (SEE REPLACEMENT )
REMOVE SUN ROOF OPENING TRIM MOLDING (w/SLIDING ROOF) (SEE REPLACEMENT )
REMOVE ROOF HEADLINING ASSY (SEE REPLACEMENT )
HINT:

It is not necessary to completely remove the roof headlining. Slightly lower the front section of the roof headlining so that the windshield glass can be removed later in step 17.
REMOVE WINDSHIELD MOLDING OUTER UPPER
1. Using a knife, cut off the molding as shown in the illustration.
  NOTE: Be careful not to damage the vehicle body with the knife.
2. Remove the remaining molding.
  
  Fig 1: Removing Windshield Molding Outer Upper
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
HINT:

Partially cut the molding. Then pull and remove it by hand.
REMOVE WINDSHIELD GLASS
HINT:

In some cases, both 1-piece type and 2-piece type stoppers are installed in the same vehicle.

Fig 2: Removing Windshield Glass (1 Of 3)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 to all wire ends.
  
  Fig 3: Removing Windshield Glass (2 Of 3)
  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.
  
  Fig 4: Removing Windshield Glass (3 Of 3)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - w/Curtain shield airbag:
    When working around the curtain shield airbag, be careful not to damage the airbag.
  - 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.
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.
CLEAN WINDSHIELD GLASS
1. Using a scraper, remove the damaged stoppers, the dam and any adhesive remaining the glass.
2. Clean the outer circumference on of the glass with white gasoline.
NOTE:
- Do not touch the glass after cleaning it.
- Even if using new glass, clean the glass with white gasoline.
Fig 5: Cleaning Windshield Glass
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 a proper fit.
    NOTE: Be careful not to damage the vehicle body.
    
    HINT:
    
    Leave as much adhesive on the vehicle body as possible.
  2. Clean the contact surface of the vehicle body with a shop rag or piece of cloth saturated with cleaner.
  HINT:
  
  Even if all the adhesive has been removed, clean the vehicle body.
  
  Fig 6: Cut Away Any Rough Adhesive On Contact Surface Of Vehicle Body To Ensure A Proper Fit Using A Knife
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL WINDSHIELD GLASS STOPPER NO.2

Coat the installation part of the stopper with Primer G.
NOTE:
- Allow the primer coating to dry for 3 minutes or more.
- Dispose of any excess Primer G.
- Do not apply too much Primer G.

Install 2 new stoppers onto the glass as shown in the illustration.

Fig 7: Installing Windshield Glass Stopper No.2

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Specification:

WINDSHIELD GLASS SPECIFICATIONS

Area	Measurement
A	7.7 mm (0.303 in.)
B	40.0 mm (1.575 in.)

INSTALL WINDSHIELD GLASS STOPPER NO.1
1. Install 2 new stoppers to the vehicle body as shown in the illustration.
  
  Fig 8: Installing Windshield Glass Stopper No. 1
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL WINDSHIELD GLASS RETAINER
1. Install 2 new retainers onto the glass as shown in the illustration.
  
  Fig 9: Installing Windshield Glass Retainer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL WINDOW GLASS ADHESIVE DAM

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.
- Dispose of any excess Primer G.
- Do not apply too much primer.

Install a new dam as shown in the illustration.

Fig 10: Installing Window Glass Adhesive Dam

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Specification:

WINDOW GLASS ADHESIVE DAM SPECIFICATIONS

Area	Measurement
a	7.0 mm (0.276 in.)
b	48.4 mm (1.905 in.)

INSTALL WINDSHIELD GLASS

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 on the glass and vehicle body.
  
  Fig 11: Install Windshield Glass
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Check that the stoppers are attached to the vehicle body correctly.
  
  HINT:
  
  When reusing the glass, check and correct the reference mark positions.
4. Using a suction cup, remove the glass.
Using a brush, coat the exposed areas of the vehicle body, where all adhesive has been removed with Primer M.
NOTE:
- Allow the primer coating to dry for 3 minutes or more.
- Do not coat the area, where adhesive is still remaining with Primer M.
- Dispose of any excess Primer M.
- Do not apply too much Primer M.
Using a brush or sponge, coat the edge of the glass and the contact surface with Primer M.
HINT:

If a non-specified area is coated by accident, wipe off the primer with a clean piece of cloth before it dries.
NOTE:
- Allow the primer coating to dry for 3 minutes or more.
- Dispose of away any excess Primer M.
- Do not apply too much Primer M.
Fig 12: Identifying Correct Way Of Applying Primer
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Apply adhesive.

Adhesive: Part No. 08850-00801 or equivalent

Cut off the tip of the cartridge nozzle as shown in the illustration.

HINT:

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

Usage time frame:

USAGE TIME FRAME

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

Load a sealer gun with the cartridge.

Coat the glass with adhesive as shown in the illustration.

Specification:

ADHESIVE SPECIFICATIONS

Area	Measurement
a	8.0 mm (0.315 in.)
b	12.0 mm (0.472 in.)

Fig 13: Applying Adhesive

Install the glass.

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 there is a small gap between the vehicle body and glass.
Lightly press the front surface of the glass to ensure that the glass is securely fit to the vehicle body.

Fig 14: Installing Glass
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using a scraper, remove any excess or protruding adhesive.

HINT:

Make sure that adhesive is applied up to the glass rim.

NOTE: The vehicle should not be driven until the time indicated in the table below has elapsed after step (3).

Minimum time:

MINIMUM TIME

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 15: Removing Adhesive

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.
  - Dispose of any excess Primer G.
  - Do not apply too much Primer G.
2. Install the molding.
INSPECT FOR LEAKS AND REPAIR
1. Conduct a leak test after the adhesive has completely hardened.
2. Seal any leaks with auto glass sealer.
INSTALL RAIN SENSOR (SEE REPLACEMENT )
INSTALL FR WIPER ARM & BLADE ASSY RH (SEE REPLACEMENT )
INSTALL FR WIPER ARM & BLADE ASSY LH (SEE REPLACEMENT )