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 table (see SPECIFIED TORQUE FOR STANDARD BOLTS ).

REMOVE FRONT WIPER ARM RH (See REPLACEMENT )
REMOVE FRONT WIPER ARM LH (See REPLACEMENT )
REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSY (See REPLACEMENT )
REMOVE DOOR SCUFF PLATE ASSY RH (See REPLACEMENT )
REMOVE DOOR SCUFF PLATE ASSY LH (See REPLACEMENT )
REMOVE FRONT DOOR OPENING TRIM COVER RH (See REPLACEMENT )
REMOVE FRONT DOOR OPENING TRIM COVER LH (See REPLACEMENT )
REMOVE FRONT PILLAR GARNISH RH (See REPLACEMENT )
REMOVE FRONT PILLAR GARNISH LH (See REPLACEMENT )
REMOVE VISOR BRACKET COVER RH (See REPLACEMENT )
REMOVE VISOR BRACKET COVER LH (See REPLACEMENT )
REMOVE RH VISOR ASSY (See REPLACEMENT )
REMOVE LH VISOR ASSY (See REPLACEMENT )
REMOVE VISOR HOLDER (See REPLACEMENT )
REMOVE MAP LAMP ASSY (See REPLACEMENT )
REMOVE ROOF FRONT CORNER HEADLINING RH (See REPLACEMENT )
REMOVE ROOF FRONT CORNER HEADLINING LH (See REPLACEMENT )
REMOVE ROOF HEADLINING ASSY (See REPLACEMENT )
REMOVE INNER REAR VIEW MIRROR STAY HOLDER COVER (See REPLACEMENT )
REMOVE INNER REAR VIEW MIRROR ASSY (See REPLACEMENT )
REMOVE FRONT BODY PILLAR ASSY OUTER RH
1. Remove the nut.
2. Using a screwdriver, detach the 5 clips and remove the pillar.
  HINT:
  
  Tape the screwdriver tip before use.
  
  Fig 1: Removing Front Body Pillar Assy Outer RH
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT BODY PILLAR ASSY OUTER LH
1. Remove the nut.
2. Using a screwdriver, detach the 5 clips and remove the pillar.
  HINT:
  
  Tape the screwdriver tip before use.
  
  Fig 2: Removing Front Body Pillar Assy Outer LH
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE WINDSHIELD MOLDING OUTSIDE RH
1. Remove the clip.
2. Remove the 3 rivets.
  1. Use a drill of less than diameter 4 mm (0.16 in.).
  2. Gently and vertically place the drill tip onto the rivet, and cut the rivet flanges.
    Specification (A): 5 mm (0.20 in.)
    NOTE:
    Do not drill the rivet at an angle as this will cause damage to the drill and drill hole. Line up the drill and rivet, and carefully drill out the rivet head.
    
    Be careful as the cut rivet will be very hot.
  3. Even if the flange is taken off, continue drilling and push out the remaining fragment with the drill.
  Fig 3: Removing Rivets
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE WINDSHIELD MOLDING OUTSIDE LH
REMOVE WINDSHIELD MOLDING OUTER UPPER
1. Using a knife, cut through 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. Apply protective tape to the outer surface of the vehicle body to prevent scratches.
2. From the interior, insert a piano wire between the vehicle body and glass as shown in Fig 5.
  
  Fig 5: Inserting Piano Wire Between Vehicle Body & Glass
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Tie objects that can serve as handles (for example, wooden blocks) to both wire ends.
  NOTE:
  - When separating the glass from the vehicle, be careful not to damage the vehicle's paint or interior/exterior ornaments.
  - To prevent the instrument panel from being scratched when removing the glass, place a plastic sheet between the piano wire and instrument panel.
4. Place matchmarks over the glass and vehicle body on the locations indicated in Fig 6.
  HINT:
  
  Matchmarks do not need to be placed if the glass is not going to be reused.
  
  Fig 6: Placing Matchmarks Over Glass & Vehicle Body
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Cut through the adhesive by pulling the piano wire around the glass.
  NOTE: Leave as much adhesive on the vehicle body as possible when cutting through the adhesive.
6. Detach the stoppers.
7. Using a suction cup, remove the glass.
CLEAN WINDSHIELD GLASS
1. Using a scraper, remove the damaged stoppers, dams and adhesive sticking to the glass.
2. Clean the outer edges of the glass with white gasoline.
  NOTE:
  - Do not touch the glass surface after cleaning it.
  - Even if using new glass, clean it 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. On the contact surface of the vehicle body, use a knife to cut away excess adhesive as shown in Fig 8.
    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 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. 1

Apply Primer G to the glass where the stoppers will be installed.
NOTE:
- Allow the Primer G 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.

Specification:

WINDSHIELD GLASS STOPPER NO. 1

Area	Measurement
a	40.0 mm (1.575 in.)
b	10.5 mm (0.413 in.)

Fig 9: 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 10.
  
  Fig 10: Installing Windshield Glass Retainer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL WINDOW GLASS ADHESIVE DAM

Apply Primer G to the glass where the adhesive dams will be installed.
NOTE:
- Allow the Primer G to dry for 3 minutes or more.
- Throw away any leftover Primer G.
- Do not apply too much Primer G.

Remove the peeling paper from the adhesive part of the dam. Install the dam (adhesive side) to the glass (Primer G area) as shown in Fig 11.

Specification:

WINDOW GLASS ADHESIVE DAM

Area	Measurement
a	7.0 mm (0.276 in.)
b	48.5 mm (1.909 in.)

Fig 11: Installing Window Glass Adhesive Dam

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL WINDSHIELD MOLDING OUTER UPPER
1. Using a brush or sponge, apply Primer G to the glass where the molding will be installed.
  NOTE:
  - Allow the Primer G to dry for 3 minutes or more.
  - Throw away any leftover Primer G.
  - Do not apply too much Primer G.
2. Install new molding before the adhesive dries.

INSTALL WINDSHIELD GLASS

Position the glass.
1. Using a suction cup, place the glass in the correct position.
2. Check that the entire contact surface of the glass rim is perfectly even.
3. Place matchmarks over the glass and vehicle body on the locations indicated.
  
  Fig 12: Placing Matchmarks Over Glass & Vehicle Body
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  - Placing matchmarks is only necessary if the glass being installed is new. If it is reused glass, matchmarks should already be present.
  - When reusing the glass, check and correct the match-mark positions.
  NOTE: Check that the stoppers are attached to the vehicle body correctly.
4. Using a suction cup, remove the glass.
Using a brush, apply Primer M to the exposed part of the vehicle body.
NOTE:
- Allow the Primer M 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 13: Applying Primer M To Exposed Part Of Vehicle Body
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using a brush or sponge, apply Primer G to the contact surface of the glass.
HINT:

If Primer G is applied to an area that is not specified, apply white gasoline to a clean cloth and wipe off the excess primer.
NOTE:
- Allow the Primer G to dry for 3 minutes or more.
- Throw away any leftover Primer G.
- Do not apply too much Primer G.
Fig 14: Applying Primer G To Contact Surface Of Glass
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Apply adhesive to the glass.

Adhesive: Part No. 08850-00801 or equivalent

Cut off the tip of the cartridge nozzle as shown in Fig 15.

HINT:

After cutting off the tip, use all adhesive within the time written in USAGE TIME FRAME .

Usage time frame:

USAGE TIME FRAME

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 15.

Specification:

MEASUREMENT TABLE

Area	Measurement
a	12.0 mm (0.472 in.)
b	8.0 mm (0.315 in.)
c	6.5 mm (0.256 in.)
d	3.0 mm (0.118 in.)

Fig 15: Coating Glass With Adhesive

Install the glass to the vehicle body.

Using a suction cup, position the glass so that the matchmarks are aligned. Press it in gently along the rim.
Lightly press the front surface of the glass to ensure that it is securely fit to the vehicle body.
NOTE:
- Check that the stoppers are attached to the vehicle body correctly.
- Check that the vehicle body and glass have a small gap between them.
Hold the glass in place securely with protective tape or equivalent until the adhesive hardens.

Fig 16: Holding Glass Securely With Protective Tape
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using a scraper, remove any excess or protruding adhesive.

Fig 17: Removing Excess Or Protruding Adhesive Using Scraper
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

Apply adhesive on the glass rim.

NOTE: Do not drive the vehicle for the amount of time written in MINIMUM TIME .

Minimum time:

MINIMUM TIME

Temperature	Minimum time prior to driving vehicle
35°C (95°F)	1.5 hours
20°C (68°F)	5 hours
5°C (41°F)	24 hours

Fig 18: Applying Adhesive On Glass Rim

INSTALL WINDSHIELD MOLDING OUTSIDE RH
1. Using an air riveter or hand riveter with nose piece, strike rivets into the body panel.
  
  Fig 19: Striking Rivets Into Body Panel Using Air Riveter Or Hand Riveter With Nose Piece
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Do not pry the rivet with the riveter, as this will cause damage to the riveter and mandrel.
    
    Fig 20: Identifying Incorrect Procedure Of Rivet (1 Of 3)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - Confirm that the rivets are seated properly against the molding outside.
  - Do not tilt the riveter when installing the rivet to the molding outside.
  - Do not leave any space between the rivet head and the molding outside.
    
    Fig 21: Identifying Incorrect Procedure Of Rivet (2 Of 3)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - Do not have any space between the molding outside and body panel. Firmly hold together the 2 items while installing the rivet.
    
    Fig 22: Identifying Incorrect Procedure Of Rivet (3 Of 3)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL WINDSHIELD MOLDING OUTSIDE LH
INSTALL FRONT BODY PILLAR ASSY OUTER RH
1. Replace the clip with a new one.
2. Install the front right body pillar assembly outer with 5 clips and nut.
INSTALL FRONT BODY PILLAR ASSY OUTER LH
CHECK FOR LEAKS AND REPAIR
1. Conduct a leak test after the adhesive has completely hardened.
2. Seal any leaks with auto glass sealer.