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Windshield Glass: Replacement

HINT:

  1. REMOVE  INNER REAR VIEW MIRROR ASSY  
  2. REMOVE ROOF HEADLINING ASSY (See  REPLACEMENT  ) 
    1. Remove the front door scuff plate LH and RH.
    2. Remove the cowl side trim LH and RH.
    3. Remove the front door opening trim weatherstrip LH and RH.
    4. Remove the front pillar garnish LH and RH.
    5. Remove the assist grip covers and assist grips.
    6. Remove the visor LH and RH.
    7. Remove the visor holder LH and RH.
    8. Remove the map lamp.
    9. 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.

  3. REMOVE COWL TOP VENTILATOR LOUVER (See  WINDSHIELD WIPER MOTOR ASSY  ) 
    1. Remove the 2 wiper head caps.
    2. Remove the front wiper arm LH and RH.
    3. Remove the hood to cowl top seal.
    4. Remove the cowl top ventilator louver LH and RH.
  4. REMOVE WINDSHIELD MOULDING OUTSIDE 
    1. Using a knife, cut off the windshield moulding outside.
      NOTE: Be careful not to damage the vehicle body with the knife.
    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. To prevent scratches, apply protective tape to the outer surface of the vehicle body and place a plastic sheet between the piano wire and instrument panel.
    2. From the interior, insert piano wires between the vehicle body and glass as shown in Fig 1 .
    3. Tie objects that can serve as handles (for example, wooden blocks) to all wire ends.
      NOTE: When separating the glass from the vehicle, be careful not to damage the vehicle's paint or interior/exterior ornaments.
    4. Place matchmarks over the glass and vehicle body on the locations indicated in Fig 1 .
      Fig 1: Applying Protective Tape To The Outer Surface Of The Vehicle Body
      G03073626Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      Matchmarks do not need to be placed if the glass is not going to be reused.

    5. Cut through the adhesive by pulling the wire around the glass.
      NOTE: Leave as much adhesive on the vehicle body as possible when cutting through the adhesive.
    6. Disengage the stoppers.
    7. Using a suction cup, remove the glass.
      Fig 2: Removing Glass Using Suction Cups
      G03073627Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. CLEAN WINDSHIELD GLASS 
    1. Using a scraper, remove the damaged stoppers, dams and adhesive from 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 3: Removing Damaged Stoppers, Dams And Adhesive From The Glass
    G03073628Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. 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 4 .

        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.
      Fig 4: Cleaning And Shape The Contact Surface Of The Vehicle Body
      G03073629Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

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

  8. INSTALL WINDSHIELD GLASS STOPPER NO. 2 
    1. Apply Primer G to the glass where the stoppers will be installed.

      HINT:

      If Primer G is applied to an area 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.
    2. Install 2 new stoppers onto the windshield glass as shown in Fig 5 .

      SPECIFICATION: 

      AREA MEASUREMENT SPECIFICATIONS

      Area Measurement
      A 7.7 mm (0.303 in.)
      B 40 mm (1.575 in.)
      C 12.5 mm (0.492 in.)
      Fig 5: Installing Windshield Glass Stopper
      G03073630Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL WINDSHIELD GLASS STOPPER NO. 1 
    1. Install 2 new stoppers to the vehicle body as shown in Fig 6 .
    Fig 6: Installing Windshield Glass Stopper No. 1
    G03073631Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL WINDSHIELD GLASS ADHESIVE DAM 
    1. Apply Primer G to the glass where the adhesive dam will be installed.

      HINT:

      If Primer G is applied to an area 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.
    2. Remove the peeling paper from the adhesive part of the dam. Install the dam (adhesive side) to the glass (Primer G area), but exclude the stopper areas C and D as shown in Fig 7 .
      Fig 7: Removing Peeling Paper From The Adhesive Part Of The Dam
      G03073632Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      SPECIFICATION: 

      AREA MEASUREMENT SPECIFICATIONS

      Area Measurement
      a 7.0 mm (0.276 in.)
  11. INSTALL WINDSHIELD GLASS 
    1. 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 in Fig 8 .

        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.
      Fig 8: Placing The Glass In The Correct Position
      G03073633Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. 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 9: Applying Primer M To The Exposed Part Of The Vehicle Body
      G03073634Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a brush or sponge, apply Primer G to the contact surface of the glass.
      Fig 10: Applying Primer G To The Contact Surface Of The Glass
      G03073635Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      If Primer G is applied to an area 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.
    4. Apply adhesive to the glass.
      1. Adhesive: Part No. 08850-00801 or equivalent 
      1. Cut off the tip of the cartridge nozzle as shown in Fig 11 .

        HINT:

        After cutting off the tip, use all adhesive within the time written in the table shown in AREA MEASUREMENT SPECIFICATION .

        USAGE TIME FRAME: 

        AREA MEASUREMENT SPECIFICATIONS

        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 glass as shown in Fig 11 .
        Fig 11: Applying Adhesive To The Glass
        G03073636Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        SPECIFICATION: 

        AREA MEASUREMENT SPECIFICATIONS

        Area Measurement
        A 12.0 mm (0.472 in.)
        B 8.0 mm (0.315 in.)
        C 3.0 mm (0.118 in.)
    5. Install the glass to the vehicle body.
      1. Using a suction cup, position the glass so that the matchmarks are aligned. Press it in gently along the rim.
      2. 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.
      3. Hold the glass in place securely with protective tape or equivalent until the adhesive hardens.
      Fig 12: Aligning Glass Matchmarks
      G03073637Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL WINDSHIELD MOULDING OUTSIDE 
    1. Using a brush or sponge, apply Primer G to the glass where the moulding will be installed.

      HINT:

      If Primer G is applied to an area 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.
    2. Install new windshield moulding outer upper before the adhesive dries.
      NOTE: Do not drive the vehicle for the amount of time written in the table shown in TEMPERATURE SPECIFICATION .

      MINIMUM TIME: 

      TEMPERATURE SPECIFICATIONS

      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. CHECK FOR LEAKS AND REPAIR 
    1. Conduct a leak test after the adhesive has completely hardened.
    2. Seal any leaks with auto sealer.
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