Section 398 (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 WINDSHIELD/WINDOW/GLASS/MIRROR (SERVICE SPECIFICATIONS) ).

1. REMOVE ROOF HEADLINING ASSY (SEE  REPLACEMENT  ) 
   1. Remove the roof side rail weatherstrip LH and RH.
   2. Remove the front door opening trim weatherstrip LH and RH.
   3. Remove the front pillar garnish LH and RH.
   4. Remove the visor LH and RH.
   5. Remove the 2 visor holders.
   6. Remove the assist grip.
   7. Remove the roof console box.
   8. Partially remove the roof headlining.

      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  5.

2. REMOVE INNER REAR VIEW MIRROR ASSY (See  REPLACEMENT  ) 
3. REMOVE COWL TOP VENTILATOR LOUVER (See  REPLACEMENT  ) 
   1. Remove the 2 windshield wiper arm covers.
   2. Remove the front wiper arm LH and RH.
   3. Remove the cowl top ventilator louver.
4. REMOVE WINDSHIELD MOULDING OUTER UPPER 
   1. Using a knife, cut off the moulding, as shown inFig 1 .
      NOTE: Be careful not to damage the vehicle body with the knife. 
      Fig 1: Cutting Off Moulding

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Remove the remaining moulding.

      HINT:

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

5. REMOVE WINDSHIELD GLASS 
   1. From the interior, insert piano wires between the vehicle body and glass, as shown inFig 2 .
      Fig 2: Inserting Piano Wires Between Vehicles Body & Glass

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Tie objects that can serve as handles (for example, wooden blocks) to all wire ends.

      HINT:

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

      Fig 3: Applying Protective Tape To Outer Surface Of Vehicle Body

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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. 
   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. 
6. CLEAN WINDSHIELD GLASS 
   1. Using a scraper, remove the damaged stoppers, dam and adhesive sticking to the glass.
      Fig 4: Removing Damaged Stoppers, Dam & Adhesive Sticking Using Scraper

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   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. 
7. 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.
         Fig 5: Cutting Away Any Rough Adhesive On Contact Surface Using Knife

         Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
         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.

         HINT:

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

8. 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 inFig 6 .
      Fig 6: Installing Stoppers Onto Windshield Glass

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Specification: 

      GLASS STOPPER SPECIFICATION TABLE
      
      

      Area	Measurement
      A	40.0 mm (1.575 in.)
      B	7.0 mm (0.276 in.)
      C	12.5 mm (0.492 in.)

9. INSTALL WINDSHIELD GLASS STOPPER NO.1 
   1. Install 2 new stoppers to the vehicle body, as shown inFig 7 .
      Fig 7: Installing Stoppers To Vehicle Body

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. INSTALL WINDSHIELD GLASS RETAINER 
    1. Install 2 new retainers onto the glass, as shown in Fig 8 .
       Fig 8: Installing Retainers Onto Glass

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
11. INSTALL WINDSHIELD 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 Fig 9 .
       Fig 9: Installing Double-Sided Tape Around Glass

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

       Specification: 

       SPECIFICATION TABLE
       
       

       Area	Measurement
       a	7.0 mm (0.276 in.)
       b (left)	60 mm (2.36 in.)
       b (center)	40 mm (1.57 in.)
       b (right)	60 mm (2.36 in.)

12. INSTALL WINDSHIELD GLASS 
    1. Position the glass.
       1. Using a suction cup, place the glass in the correct position.
          Fig 10: Placing Glass In Correct Position

          Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
       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 positions.

       4. Using a suction cup, remove the glass.
    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 11: Using Brush To Coat Exposed Part Of Vehicle Body On Vehicle Side With Primer M

         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 12: Using Brush Or Sponge To Coat Edge Of Glass & Contact Surface With Primer G

         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 Fig 13 .

          HINT:

          After cutting off the tip, use all adhesive within the time described in TEMPERATURE TABLE  .

          Usage timeframe: 

          TEMPERATURE TABLE
          
          

          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 Fig 13 .

          Specification: 

          SPECIFICATION TABLE
          
          

          Area	Measurement
          a	3.0 mm (0.118 in.)
          b	12.0 mm (0.472 in.)
          c	8.0 mm (0.315 in.)
          d	16.0 mm (0.630 in.)

          Fig 13: Applying Adhesive To Glass

          Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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 14: Positioning Glass Aligning With Reference Marks

          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. 
          Fig 15: Removing Excess Or Protruding Adhesive

          Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

          Minimum time: 

          TEMPERATURE 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

13. INSTALL WINDSHIELD MOULDING 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 moulding.
14. CHECK FOR LEAKS AND REPAIR 
    1. Conduct a leak test after the adhesive has completely hardened.
    2. Seal any leaks with auto glass sealer.