Windshield Glass: Replacement

HINT:

Follow the same procedures as for the fender to cowl side seal LH.

1. Separate the front door opening trim weatherstrip to the extent which allows the removal of the front pillar garnish.

HINT:

Follow the same procedures as for the front door opening trim weatherstrip LH.

HINT:

• Regular cab: See REPLACEMENT
• Access cab: See REPLACEMENT
• Double cab: See REPLACEMENT

HINT:

Follow the same procedures as for the front pillar garnish LH.

HINT:

• Access cab: See REPLACEMENT
• Double cab: See REPLACEMENT

HINT:

• Regular cab: See REPLACEMENT
• Access cab: See REPLACEMENT
• Double cab: See REPLACEMENT

HINT:

Follow the same procedures as for the LH visor.

HINT:

• Regular cab: See REPLACEMENT
• Access cab: See REPLACEMENT
• Double cab: See REPLACEMENT

1. Using a knife, cut off the windshield moulding outer upper, as shown in the illustration.
   NOTE: Be careful not to damage the vehicle body with the knife.
2. Remove the windshield moulding outer upper.

   HINT:

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

   Fig 1: Cutting Off Windshield Moulding Outer Upper Using Knife

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Apply protective tape to the outer circumference of the windshield glass, as shown in the illustration.
2. From the interior, insert piano wires between the vehicle body and windshield glass, as shown in the illustration.
3. Tie objects that can serve as handles (for example, wooden blocks) to all wire ends.
   NOTE:

   • When separating the windshield glass from the vehicle, be careful not to damage the vehicle's paint or exterior/interior ornaments.
   • To prevent the safety pad from being scratched when removing the windshield glass, place a plastic sheet between the piano wire and safety pad.
4. Cut through the adhesive by pulling the piano wire around the windshield glass.
   Fig 2: Applying Protective Tape To Outer Circumference Of Windshield Glass

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Disengage the 2 stoppers.
6. Using suction cups, remove the windshield glass.
   NOTE: Leave as much adhesive on the vehicle body as possible when removing the windshield glass.
   Fig 3: Removing Windshield Glass Using Suction Cups

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a scraper, remove the damaged stoppers, dam and adhesive stuck to the windshield glass.
2. Clean the outer circumference of the windshield glass with white gasoline.

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.
      NOTE: Be careful not to damage the vehicle body.

      HINT:

      Leave as much adhesive on the vehicle body as possible.

      Fig 5: Cutting Away Any Rough Adhesive On Contact Surface Of Vehicle

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

      HINT:

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

1. Apply Primer G to the installation part of the stoppers.
   NOTE:

   • Allow the primer 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 windshield glass, as shown in the illustration.

   Specification: 

   AREA MEASUREMENT SPECIFICATION
   
   

   Area	Measurement
   A	40 mm (1.575 in.)
   B	9.4 mm (0.37 in.)
   C	12.5 mm (0.482 in.)

   Fig 6: Installing Stoppers Onto Windshield Glass

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install 2 new stoppers onto the vehicle body, as shown in the illustration.
   Fig 7: Installing Stoppers Onto Vehicle Body

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Apply Primer G to the illustration part of the dam.
   NOTE:

   • Allow the primer to dry for 3 minutes or more.
   • Throw away any leftover Primer G.
   • Do not apply too much Primer G.
2. Install 3 new dams. Install the 3 new dams by applying double-sided tape all the way around the windshield glass except where the stoppers are installed, as shown in the illustration.
   Fig 8: Installing Dams By Applying Double-Sided Tape Around Windshield Glass

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Specification: 

   AREA MEASUREMENT SPECIFICATION
   
   

   Area	Measurement
   a	7.0 mm (0.276 in.)
   b	30.9 mm (1.217 in.)

1. Position the windshield glass.
   1. Using suction cups, place the windshield glass in the correct position.
   2. Check that the whole contact surface of the windshield glass rim is perfectly even.
   3. Place matchmarks over the windshield glass and vehicle body.
      NOTE: Check that the stoppers are attached to the vehicle body correctly.

      HINT:

      When reusing the windshield glass, check and correct the matchmark positions.

      Fig 9: Placing Windshield Glass In Correct Position Using Suction Cups

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   4. Using suction cups, remove the windshield glass.
2. Using a brush, apply Primer M to the exposed part of the vehicle body.
   NOTE:

   • Allow the primer to dry for 3 minutes or more.
   • Do not apply Primer M to the adhesive.
   • Throw away any leftover Primer M.
   • Do not apply too much Primer M.
     Fig 10: Applying Primer M To Exposed Part Of Vehicle Body Using Brush

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a brush or sponge, apply Primer G to the edge of the windshield glass and contact surface.
   NOTE:

   • Allow the primer to dry for 3 minutes or more.
   • Throw away any leftover Primer G.
   • Do not apply too much Primer G.

     HINT:

     If Primer G is applied to any areas other than that which is specified, wipe off the primer with a clean shop rag before it dries.

     Fig 11: Applying Primer G To Edge Of Windshield Glass And Contact Surface

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

   Adhesive: Part No. 08850-00801 or equivalent 

   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 times indicated in the table bellow.

      Usage time frame: 

      TEMPERATURE SPECIFICATION
      
      

      Temperature	Usage Time Frame
      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. Apply adhesive to the windshield glass as shown in the illustration.

      Specification: 

      TEMPERATURE SPECIFICATION
      
      

      Area	Measurement
      a	8 mm (0.315 in.)
      b	12 mm (0.472 in.)
      c	3 mm (0.118 in.)
      d	26.9 mm (1.059 in.)

      Fig 12: Applying Adhesive

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Install the windshield glass onto the vehicle body.
   1. Using suction cups, position the windshield glass so that the matchmarks are aligned. Press it in gently along the rim
      NOTE:

      • Allow the primer to dry for 3 minutes or more.
      • Check that the stoppers are attached to the vehicle body correctly.
      • Check that the vehicle body and windshield glass have a small gap between them.
        Fig 13: Aligning Matchmark

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

      HINT:

      Apply adhesive to the windshield glass rim.

      Fig 14: Removing Excessive Or Protruding Adhesive Using Scraper

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a brush or sponge, apply Primer G to the edge of the windshield glass and contact surface.
   NOTE:

   • Allow the primer to dry for 3 minutes or more.
   • Throw away any leftover Primer G.
   • Do not apply too mush Primer G.
2. Install the windshield moulding outer upper before the adhesive dries.
   NOTE: Do not drive vehicle for the amount of time indicated in the table below.

   Minimum time: 

   AREA MEASUREMENT SPECIFICATION
   
   

   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: Applying Primer G To Edge Of Windshield Glass And Contact Surface

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

Follow the same procedures as for the fender to cowl side seal LH.

1. Conduct a leak test after the adhesive has completely hardened.
2. Seal any leakage with auto glass sealer.

HINT:

• Regular cab: See REPLACEMENT
• Access cab: See REPLACEMENT
• Double cab: See REPLACEMENT

HINT:

• Regular cab: See REPLACEMENT
• Access cab: See REPLACEMENT
• Double cab: See REPLACEMENT

HINT:

Follow the same procedures as for the LH visor.

HINT:

• Access cab: See REPLACEMENT
• Double cab: See REPLACEMENT

HINT:

• Regular cab: See REPLACEMENT
• Access cab: See REPLACEMENT
• Double cab: See REPLACEMENT

HINT:

Follow the same procedures as for the front pillar garnish LH.

1. Install the front door opening trim weatherstrip.

HINT:

Follow the same procedures as for the front opening trim weatherstrip LH.

Torque: 3.9 N.m (40 kgf.cm, 35 in.lbf)