Windshield Glass: Replacement

1. Remove the front door weatherstrip LH.
2. Remove the front door weatherstrip RH.
3. Remove the 2 assist grips.
4. Remove the front pillar garnish LH.
5. Remove the front pillar garnish RH.
6. Remove the LH Visor assy.
7. Remove the RH Visor assy.
8. Remove the LH visor.
9. Remove the RH visor.
10. Remove the 2 visor holders.
11. Remove the roof console box assy.
12. Remove the roof headlining assy.

1. Remove the 2 front wiper arm head caps.
2. Remove the FR wiper arm LH.
3. Remove the FR wiper arm RH.
4. Remove the front fender to cowl side seal LH.
5. Remove the front fender to cowl side seal RH.
6. Remove the cowl top ventilator louver.

NOTE: Do not damage the body with the knife.
Fig 1: Using Knife, Cut Off Moulding
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Using a knife, cut off the moulding as shown in Fig 2.
2. Remove the remaining moulding.
   NOTE:

   When removing, make a cut partly, pull and remove it by hand.

1. Pass a piano wire through between the body and glass from the interior.
   Fig 2: Passing Piano Wire Through Between Body And Glass From Interior

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
NOTE:

Apply protective tape to the outer surface to prevent the surface from being scratched.

Fig 3: Removing Glass, Place A Plastic Sheet Between Piano Wire And Safety Pad.
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
NOTE:
• When separating the glass, take care not to damage the paint and the interior and exterior ornaments.
• To prevent scratching the safety pad when removing the glass, place a plastic sheet between the piano wire and safety pad.
2. Tie both wire ends to wooden blocks or similar objects.
3. Cut off the adhesive by pulling the piano wire around the glass.
4. Disengage the stoppers.
5. Using a suction rubber, remove the glass.
   NOTE: Leave as much adhesive on the body as possible when removing the glass.

1. Using a scraper, remove the damaged stoppers, dam and adhesive sticking to the glass.
   Fig 4: Removing Damaged Stoppers, Dam And Adhesive Sticking To Glass Using Scraper

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Clean the outer circumference of the glass with white gasoline.

1. Coat the installation part of the stopper with Primer G.
   NOTE:

   • Dry the primer coating for 3 minutes or more.
   • Do not keep any of the opened Primer G for later use.
   • Do not apply too much primer.
2. Install the 2 new windshield glass stoppers No.2 onto the glass as shown in Fig 5.
   Fig 5: Installing 2 Windshield Glass Stoppers No. 2 Onto Glass

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   DIMENSION
   
   

   Location	Specification
   A	40.0 mm (1.575 in.)
   B	7.8 mm (0.307 in.)

1. Install 2 new windshield glass stoppers No. 1 to the body, as shown in Fig 6.
   Fig 6: Installing 2 Windshield Glass Stoppers No. 1 To Body

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Coat the installation part of the window glass adhesive dam with Primer G.
   NOTE:

   • Dry the primer coating for 3 minutes or more.
   • Do not apply too much primer.
2. Install new dam with double-stick tape all the way around the glass except where the dam is installed, as shown in Fig 7.
   Fig 7: Installing Dam With Double-Stick Tape All Way Around Glass Except Where Dam Is Installed

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Dimension: 

1. Using a brush or sponge, coat the edge of the glass and the contact surface with Primer G.
   NOTE:

   • Dry the primer coating for 3 minutes or more.
   • Do not coat the adhesive with Primer G.
   • Do not keep any of the opened Primer G for later use.
2. Install the windshield moulding outer upper.

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 body to shape the surface.
      Fig 8: Locating Adhesive

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Leave as much adhesive on the body as possible.

   NOTE:

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

   2. Clean the contact surface of the body with a piece of shop rag saturated with cleaner.
2. Position the glass.
   1. Using a suction rubber, place the glass in the correct position.
   2. Check that the whole contact surface of the glass rim is perfectly even.
   NOTE: Check that the stoppers are attached to the body correctly.
   When reusing the glass, check and correct the reference mark positions.
   Fig 9: Placing Reference Marks Between Glass And Body
   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. Place reference marks between the glass and body.
   4. Remove the glass.
3. Using a brush, coat the exposed part of the body on the vehicle side with Primer M.
   Fig 10: Coating Exposed Part Of Body On Vehicle Side With Primer M Using Brush

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE:

   • Dry the primer coating for 3 minutes or more.
   • Do not coat the adhesive with Primer M.
   • Do not keep any of the opened Primer M for later use.
NOTE:

If the area other than the specified is coated by accident, wipe off the primer with a clean shop rag before it dries.

Fig 11: Coating Edge Of Glass And Contact Surface With Primer G Back Side
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
NOTE:
• Dry the primer coating for 3 minutes or more.
• Do not keep any of the opened Primer G for later use.
4. Using a brush or sponge, coat the edge of the glass and the contact surface with Primer G.
5. 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 TACK FREE TIME .

      TACK FREE TIME
      
      

      Temperature	Tackfree Time
      35°C (95°F)	15 minutes
      20°C (68°F)	100 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 12.
      Fig 12: Cutting Off Tip Of Cartridge Nozzle Back Side

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      DIMENSION
      
      

      A	12.0 mm (0.472 in.)
      B	8.0 mm (0.315 in.)
      C	3.0 mm (0.118 in.)
      D	24.9 mm (0.980 in.)

      Fig 13: Positioning Glass So Reference Marks Are Aligning, And Pressing It In Gently Along Rim

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

6. Install the glass.
   1. Using a suction rubber, position the glass so that the reference marks are aligned, and press it in gently along the rim.
      NOTE:

      • Dry the primer coating for 3 minutes or more.
      • Check that the stoppers are attached to the body correctly.
      • Check the clearance between the body and glass.
   2. Lightly press the glass front surface for close contact.
   3. Using a scraper, remove any excess or protruding adhesive.
      Fig 14: Removing Any Excess Or Protruding Adhesive Using Scraper

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE:

   Apply adhesive onto the glass rim.

   Fig 15: Applying Adhesive Onto Glass Rim

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   CAUTION: Take care not to drive the vehicle during the time described in 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

1. Conduct a leak test after the adhesive has completely hardened.
2. Seal any leaks with auto glass sealer.