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 rood 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.

1. Using a knife, cut off the moulding as shown in Fig 1 .
   NOTE: Do not damage the body with the knife.
2. Remove the remaining moulding.

HINT:

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

Fig 1: Cutting Off Moulding

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Tie both wire ends to wooden blocks or similar objects.
   Fig 3: Tying Both Wire Ends To Wooden Blocks

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   HINT:

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

   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.
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.

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.

Fig 4: Cleaning Windshield Glass

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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 Windshield Glass Stopper No. 2 Onto Glass

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Dimension: 

1. Install 2 new windshield glass stoppers No. 1 to the body, as shown in Fig 6 .

Fig 6: Installing Windshield Glass Stopper No. 1

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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 Window Glass Adhesive Dam

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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.

      HINT:

      Leave as much adhesive on the body as possible.

      Fig 8: Identifying Adhesive

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Clean the contact surface of the body with a piece of shop rag saturated with cleaner.

   HINT:

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

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.
   3. Place reference marks between the glass and body.
      NOTE: Check that the stoppers are attached to the body correctly.
      Fig 9: Placing Reference Marks Between Glass And Body

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      When reusing the glass, check and correct the reference mark positions.

   4. Remove the glass.
3. Using a brush, coat the exposed part of the body on the vehicle side with Primer M.
   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.
   Fig 10: Coating Exposed Part Of Body On Vehicle Side With Primer M

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a brush or sponge, coat the edge of the glass and the contact surface with Primer G.
   NOTE: If the area other than the specified is coated by accident, wipe off the primer with a clean shop rag before it dries.

   HINT:

   • Dry the primer coating for 3 minutes or more.
   • Do not keep any of the opened Primer G for later use.
   Fig 11: Coating Edge Of Glass And Contact Surface With Primer Using Brush Or Sponge

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Apply adhesive.

   Adhesive: Part No. 08850-00801 or equivalent 

   1. Cut off the tip of the cartridge nozzle as shown in Fig 12 .
      Fig 12: Cutting Off Tip Of Cartridge Nozzle

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      After cutting off the tip, use all adhesive within the time described in TACKFREE TIME DESCRIPTION  .

      Tackfree time: 

      TACKFREE TIME DESCRIPTION
      
      

      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 .

   Dimension: 

   WINDSHIELD GLASS DIMENSION CHART
   
   

   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.)

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.
      Fig 13: Positioning Glass Using Suction Rubber

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Lightly press the glass front surface for close contact.
   3. Using a scraper, remove any excess or protruding adhesive.

Fig 14: Removing Excess Or Protruding Adhesive Using Scraper

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HINT:

Apply adhesive onto the glass rim.

NOTE: Take care not to drive the vehicle during the time described in MINIMUM TIME CHART  .

Fig 15: Applying Adhesive Onto Glass Rim

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Minimum time: 

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