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Windshield Glass: Replacement

HINT:

  1. REMOVE FR WIPER ARM RH (See  REPLACEMENT  ) 
  2. REMOVE FR WIPER ARM LH (See  REPLACEMENT  ) 
  3. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSY (See  REPLACEMENT  ) 
  4. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP RH (See  REPLACEMENT  ) 
  5. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP LH (See  REPLACEMENT  ) 
  6. REMOVE FRONT PILLAR GARNISH RH (w/o CURTAIN SHIELD AIR BAG) (See step 33 on  REPLACEMENT  ) 
  7. REMOVE FRONT PILLAR GARNISH LH (w/o CURTAIN SHIELD AIR BAG) (See step 34 on  REPLACEMENT  ) 
  8. REMOVE FRONT PILLAR GARNISH RH (w/ CURTAIN SHIELD AIR BAG) (See step 35 on  REPLACEMENT  ) 
  9. REMOVE FRONT PILLAR GARNISH LH (w/ CURTAIN SHIELD AIR BAG) (See step 36 on  REPLACEMENT  ) 
  10. REMOVE ROOF CONSOLE BOX ASSY (See step 40 on  REPLACEMENT  ) 
  11. REMOVE RH VISOR ASSY (See step 38 on  REPLACEMENT  ) 
  12. REMOVE LH VISOR ASSY (See step 39 on  REPLACEMENT  ) 
  13. REMOVE VISOR HOLDER (See step 42 on  REPLACEMENT  ) 
  14. REMOVE ROOF HEADLINING ASSY (See step 44 on  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.

  15. REMOVE INNER REAR VIEW MIRROR ASSY (See  REPLACEMENT  ) 
  16. 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.

    HINT:

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

    Fig 1: Removing Windshield Molding Outer Upper
    G04394516Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
  17. REMOVE WINDSHIELD GLASS 

    HINT:

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

    Fig 2: Identifying Stoppers
    G04394517Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
    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 3: Inserting Piano Wires Between Vehicle Body And Glass
      G04394518Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

      HINT:

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

      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.
      Fig 4: Placing Plastic Sheet Between Piano Wire And Safety Pad
      G04394519Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
    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.
  18. 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 after cleaning it.
    • Even if using new glass, clean the glass with white gasoline.
    Fig 5: Cleaning Windshield Glass
    G04394520Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
  19. 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.
        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 piece of shop rag saturated with cleaner.
      Fig 6: Cutting Away Rough Adhesive On Vehicle Body
      G04394521Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

      HINT:

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

  20. 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.
      • 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.
      3. Fig 7: Installing Windshield Glass Stopper No. 2
      G04394522Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

    Specification: 

    STOPPER SPECIFICATION TABLE

    Area Measurement
    A 7.7 mm (0.303 in.)
    B 40.0 mm (1.575 in.)
  21. 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
    G04394523Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
  22. INSTALL WINDSHIELD GLASS RETAINER 
    1. Install 2 new retainers onto the glass, as shown in the illustration.
    Fig 9: Installing Windshield Glass Retainer
    G04394524Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
  23. 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.
    2. Install a new dam, as shown in the illustration.
      3. Fig 10: Installing Window Glass Adhesive Dam
      G04394525Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

    Specification: 

    DAM SPECIFICATION TABLE

    Area Measurement
    a 7.0 mm (0.276 in.)
    b 35.0 mm (1.378 in.)
  24. 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.
        NOTE: Check that the stoppers are attached to the vehicle body correctly.

        HINT:

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

      4. Using a suction cup, remove the glass.
      Fig 11: Placing Reference Marks Between Glass And Vehicle Body
      G04394526Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
    2. Using a brush, coat the exposed part of the vehicle body on the vehicle side 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 12: Coating Vehicle Body With Primer M
        G04394527Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
    3. Using a brush or sponge, coat the edge of the glass and the contact surface with Primer G.

      HINT:

      If the 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.
    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 time described in the table below.

        Usage time frame: 

        ADHESIVE - USAGE TIME FRAME TABLE

        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. Coat the glass with adhesive, as shown in the illustration.
        4. Fig 13: Coating Glass With Adhesive
        G04394528Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

      Specification: 

      ADHESIVE SPECIFICATION TABLE

      Area Measurement
      a 8.0 mm (0.315 in.)
      b 12.0 mm (0.472 in.)
    5. Install the glass.
      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.
      2. Lightly press the front surface of the glass to ensure that the glass is securely fit to the vehicle body.
        Fig 14: Aligning Glass Reference Marks Using A Suction Cup
        G04394529Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
      3. Using a scraper, remove any excess or protruding adhesive.
        4. Fig 15: Removing Excess Adhesive Using A Scraper
        G04394530Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

      HINT:

      Apply adhesive on the glass rim.

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

      Minimum time: 

      ADHESIVE - TIME PRIOR TO DRIVING VEHICLE TABLE

      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
  25. 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.
      • Throw away any leftover Primer G.
      • Do not apply too much Primer G.
    2. Install the molding.
  26. CHECK FOR LEAKS AND REPAIR 
    1. Conduct a leak test after the adhesive has completely hardened.
    2. Seal any leaks with auto glass sealer.
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