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 SPECIFIED TORQUE FOR STANDARD BOLTS ).

REMOVE ROOF HEADLINING ASSY (See step 37 in REPLACEMENT )
1. Remove the front door opening trim weatherstrip LH and RH.
2. Remove the front pillar garnish LH and RH.
3. w/ Rain sensor:
  Remove the rain sensor.
  1. Pull the stopper downward to release it, as shown in Fig 1 , and remove the rain sensor.
  2. Disconnect the connector.
  Fig 1: Removing Rain Sensor
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the inner rear view mirror together with the center visor.
5. Remove the map lamp.
6. Remove the visor LH and RH.
7. Remove the 2 visor holders.
8. Remove the assist grip.
9. Partially remove the roof headlining.
HINT:

Do not remove the roof headlining completely. Slightly lower the front section of the roof headlining so that the windshield glass can be removed later in step 8.
REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSY (See step 5 in REPLACEMENT )
1. Remove the hood to cowl top seal.
2. Remove the 2 pillar pads No. 4.
3. Remove the front wiper arm LH and RH.
4. Remove the cowl top ventilator louver.
w/ Water pipe:
DISCONNECT WATER PIPE

NOTE: When disconnecting the water pipe, be sure to cover the water pipe with a cloth to prevent coolant from spilling onto other parts.
REMOVE WINDSHIELD MOLDING OUTSIDE LH
1. Using a molding remover, remove the windshield molding outside.
Fig 2: Removing Windshield Molding Outside
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE WINDSHIELD MOLDING OUTSIDE RH
HINT:

Use the same procedures described for the LH side.
REMOVE WINDSHIELD MOLDING OUTSIDE CLIP
1. Using a drill of less than phis 4 mm (0.16 in.), gently and perpendicularly place the drill tip onto the rivet and cut the rivet flanges.
  HINT:
  
  Wind tape around the drill blade so that the drill blade appears approximately 5 mm (0.20 in.) on the edge.
  NOTE:
  - Be sure to gently place the drill perpendicular to the rivet to prevent the rivet hole and the drill itself from being damaged.
  - Be careful as the cut rivet will be very hot.
2. Even if the flange is taken off, continue drilling and push cut the remaining fragment with the drill.
3. Remove the 10 windshield molding outside clips.
Fig 3: Removing Windshield molding Outside Clip
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE WINDSHIELD MOLDING OUTER UPPER
1. Using a knife, cut off the molding, as shown in Fig 4 .
  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 4: Removing Windshield Molding Outer Upper
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE WINDSHIELD GLASS
1. From the interior, insert piano wires between the vehicle body and glass, as shown in Fig 5 .
  
  Fig 5: Inserting Piano Wires Between Vehicle Body And 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 6: 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.
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.
- Even if using new glass, clean the glass with white gasoline.
Fig 7: 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 the appropriate surface shape.
    HINT:
    
    Leave as much adhesive on the vehicle body as possible.
    
    NOTE: Be careful not to damage the vehicle body.
  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.
  
  Fig 8: Cleaning Vehicle Body
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL WINDSHIELD GLASS STOPPER NO. 2

Coat the installation part of the stoppers 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.
Install 2 new stoppers onto the glass, as shown in Fig 9 .

Fig 9: Installing Windshield Glass Stopper No. 2

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Specification:

WINDSHIELD GLASS STOPPER NO. 2

Area	Measurement
A	9.1 mm (0.358 in.)
B	40.0 mm (1.575 in.)
C	12.5 mm (0.492 in.)

INSTALL WINDSHIELD GLASS STOPPER NO. 1
1. Install 2 new stoppers to the vehicle body, as shown in Fig 10 .
Fig 10: 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 Fig 11 .
Fig 11: 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.
- Throw away any leftover Primer G.
- Do not apply too much Primer G.
Install a new dam, applying double-sided tape all the way around the glass except where the stoppers are installed, as shown in Fig 12 .

Fig 12: Installing Window Glass Adhesive Dam

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Specification:

WINDOW GLASS ADHESIVE DAM

Area	Measurement
A	7 mm (0.276 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 between the glass and vehicle body.
  HINT:
  
  When reusing the glass, check and correct the reference mark positions.
  
  NOTE: Check that the stoppers are attached to the vehicle body correctly.
4. Remove the glass.
Fig 13: Positioning Glass Using Suction Cup
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.
- Throw away any leftover Primer M.
- Do not apply too much Primer M.
Fig 14: 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.
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 15: Coating Edge Of Glass And Contact Surface With Primer G
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Apply adhesive.

Adhesive: Part No. 08850-00801 or equivalent

Fig 16: Applying Adhesive (W/O Water Pipe)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Fig 17: Applying Adhesive (W/Water Pipe)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Cut off the tip of the cartridge nozzle, as shown in Fig 16 and Fig 17 .

HINT:

After cutting off the tip, use all adhesive within the time described in USAGE TIMEFRAME REFERENCE TABLE .

Usage timeframe:

USAGE TIMEFRAME REFERENCE TABLE

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

Load the sealer gun with the cartridge.
Coat the glass with adhesive, as shown in Fig 16 and Fig 17 .

Specification:

MEASUREMENT AREA SPECIFICATION TABLE

Area	Measurement
a	12.5 mm (0.492 in.)
b	8.0 mm (0.315 in.)
c	3.0 mm (0.118 in.)

Install the glass to the vehicle body.

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 18: Positioning Glass Using Suction Cup
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Lightly press the front surface of the glass to ensure that the glass is securely fit to the vehicle body.
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 19: Removing Excess Or Protruding Adhesive

Minimum time:

TEMPERATURE/DRIVE TIME FRAME 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

CHECK FOR LEAKS AND REPAIR
1. Conduct a leak test after the adhesive has completely hardened.
2. Seal any leaks with auto glass sealer.
INSTALL WINDSHIELD molding OUTER UPPER
1. Apply adhesive to the molding installation area between the glass and the vehicle body.
  
  Fig 20: Applying Adhesive To Molding Installation Area
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Place new molding onto the vehicle body and tap it by hand.
Fig 21: Placing Molding On Vehicle Body
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL WINDSHIELD GLASS SEAL
1. Clean the installation area.
2. Attach new seals, as shown in Fig 22 .
Fig 22: Installing Windshield Glass Seal
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL WINDSHIELD MOLDING OUTSIDE CLIP
1. Using an air riveter equipped with a nose piece, strike rivets into the body panel to install the windshield molding outside clips to the body panel, as shown in Fig 23 .
Fig 23: Installing Windshield Molding Outside Clip
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE: Position the rivets perpendicularly to the surface. Using the riveter on an incorrectly positioned rivet will bend and damage the rivet's mandrel.

Fig 24: Positioning Rivets Perpendicularly To Surface
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL WINDSHIELD MOLDING OUTSIDE LH
1. Install the windshield molding outside, as shown in Fig 25 .
INSTALL WINDSHIELD MOLDING OUTSIDE RH
1. Use the same procedures described for the LH side.

w/ Rain sensor:

INSTALL RAIN SENSOR

If reusing the rain sensor:

Install new rain sensor tape.

Remove the used rain sensor tape from the windshield glass or rain sensor.
Apply new rain sensor tape on the rain sensor lens surface, indicated by the diagonal lines in Fig 26 .

NOTE:

Keep the tape's exposed adhesive free from dust and fingerprints.
Apply the tape exactly according to the measurements. Do not apply tape outside of the specified area.

Fig 26: Installing Rain Sensor (W/Rain Sensor)

Specification:

RAIN SENSOR TAPE

Area	Measurement
A	10.0 mm (0.394 in.)
B	11.0 mm (0.433 in.)

Install the rain sensor.
NOTE:
- If reusing the windshield glass:
  Make sure that the windshield glass has no residual rain sensor tape from the rain sensor removal process. Remove the tape if necessary.
- Clean the glass surface with a cloth.
1. Connect the connector.
2. Peel the separation paper from the rain sensor tape.
3. Securely attach the rain sensor to the bracket.
4. Push the stopper upward.
Fig 27: Installing Rain Sensor
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

w/ Water pipe:
CONNECT WATER PIPE
w/ Water pipe:
REFILL ENGINE COOLANT (See REPLACEMENT )
w/ Water pipe:
CHECK FOR ENGINE COOLANT LEAKS (See ON-VEHICLE INSPECTION )