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 ROOF HEADLINING ASSY (See 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.
REMOVE INNER REAR VIEW MIRROR ASSY (See REPLACEMENT )
REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSY (See REPLACEMENT )
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.
REMOVE WINDSHIELD MOLDING OUTSIDE LH (See REPLACEMENT )
REMOVE WINDSHIELD MOLDING OUTSIDE RH (See REPLACEMENT )
REMOVE WINDSHIELD MOLDING OUTER UPPER
1. Using a knife, cut off the molding as shown in Fig 1.
  NOTE: Do not damage the body with the knife.
2. Remove the remaining molding.
  HINT:
  
  When removing, make a cut partly, pull and remove it by hand.
  
  Fig 1: Cutting Off Molding
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE WINDSHIELD GLASS
1. Pass a piano wire through between the body and glass from the interior.
  
  Fig 2: Passing Piano Wire Through Between Body & Glass
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Tie both wire ends to wooden blocks or similar objects.
  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.
    
    Fig 3: Tying Both Wire Ends To Wooden Blocks
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
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.
  - Be careful not to damage the body.
    
    Fig 4: Removing Damaged Stoppers, Dam & Adhesive Sticking To Glass
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL WINDSHIELD GLASS STOPPER NO.2

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.

Install the 2 new windshield glass stoppers No.2 onto the glass.

Dimension:

WINDSHIELD GLASS STOPPERS DIMENSION

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

Fig 5: Installing Windshield Glass Stoppers No. 2 Onto Glass

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL WINDSHIELD GLASS STOPPER NO.1
1. Install 2 new windshield glass stoppers No. 1 to the body as shown in Fig 6.
  
  Fig 6: Identifying New Windshield Glass Stoppers No.1
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL WINDOW GLASS ADHESIVE DAM

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.

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

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Dimension:

DOUBLE-STICK TAPE DIMENSION TABLE

C	9.5 mm (0.374 in.)
D	31.4 mm (1.236 in.)

INSTALL WINDSHIELD MOLDING OUTER UPPER
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 molding outer upper.

INSTALL WINDSHIELD GLASS

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.
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.
  
  Fig 8: Identifying Adhesive Contact Surface Of Body
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
  
  HINT:
  
  When reusing the glass, check and correct the reference mark positions.
  
  Fig 9: Placing Reference Marks Between Glass & Body
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the glass.
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
  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 the area other than the specified is coated by accident, wipe off the primer with a clean shop rag before it dries.
NOTE:
- 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 & Contact Surface With Primer G
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Apply adhesive.

Adhesive: Part No. 08850-00801 or equivalent

Cut off the tip of the cartridge nozzle as shown in Fig 12.

HINT:

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

Tackfree time:

TEMPERATURE TACKFREE TIME TABLE

Temperature	Tackfree Time
35°C (95°F)	15 minutes
20°C (68°F)	100 minutes
5°C (41°F)	8 hours

Load the sealer gun with the cartridge.

Coat the glass with adhesive.

Dimension:

SEALER GUN DIMENSION TABLE

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 12: Cutting Off Tip Of Cartridge Nozzle

Install the glass.

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

Fig 13: Aligning Reference Marks
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
Lightly press the glass front surface for close contact.

Using a scraper, remove any excess or protruding adhesive.

Fig 14: Removing Excess Or Protruding Adhesive Using Scraper

HINT:

Apply adhesive onto the glass rim.

Fig 15: Applying Adhesive Onto Glass Rim

NOTE: Take care not to drive the vehicle during the time described in TEMPERATURE TIME PRIOR TABLE .

Minimum time:

TEMPERATURE TIME PRIOR TABLE

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

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