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Windshield Glass: Replacement

NOTE: The installation is in the reverse order of the removal. However, when there is a special point concerning the installation, it is indicated.
  1. REMOVE FR WIPER ARM LH (See step 2 under  REPLACEMENT  ) 
  2. REMOVE FR WIPER ARM RH 
  3. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSY (See step 4 under  REPLACEMENT  ) 
  4. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP RH 
  5. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP LH 
  6. REMOVE FRONT PILLAR GARNISH RH (W/O CURTAIN SHIELD AIR BAG) (See step 31 under  REPLACEMENT  ) 
  7. REMOVE FRONT PILLAR GARNISH LH (W/O CURTAIN SHIELD AIR BAG) 
  8. REMOVE FRONT PILLAR GARNISH RH (W/ CURTAIN SHIELD AIR BAG) (See step 33 under  REPLACEMENT  ) 
  9. REMOVE FRONT PILLAR GARNISH LH (W/ CURTAIN SHIELD AIR BAG) 
  10. REMOVE ROOF CONSOLE BOX ASSY (See step 38 under  REPLACEMENT  ) 
  11. REMOVE RH VISOR ASSY (See step 36 under  REPLACEMENT  ) 
  12. REMOVE LH VISOR ASSY 
  13. REMOVE VISOR HOLDER (See step 40 under  REPLACEMENT  ) 
  14. REMOVE ROOF HEADLINING ASSY (See step 42 under  REPLACEMENT  ) 
  15. REMOVE INNER REAR VIEW MIRROR ASSY (See step 1 under  REPLACEMENT  ) 
  16. REMOVE WINDSHIELD MOLDING OUTER UPPER 
    1. Using a knife, cut off the molding as shown in Fig 1.
      Fig 1: Cutting Off Wind Shield Molding
      G02823585Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      CAUTION: Do not damage the body with the knife.
    2. Remove the remaining molding.
      NOTE: When removing, make a cut partly, pull and remove it by hand.
  17. REMOVE WINDSHIELD GLASS 
    NOTE: There is a case where a 1-piece type and a 2-piece type of stoppers are installed in a vehicle type.
    Fig 2: Identifying 1-Piece And 2-Piece Type Stoppers
    G02823586Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Pass piano wire through between the body and glass from the interior.
    2. Tie both wire ends to wooden blocks or similar objects.
      NOTE: Apply protective tape to the outer surface to prevent the surface from being scratched.
      CAUTION:
      • w/ Curtain shield airbag:

        When working around the curtain shield airbag, be careful not to damage the airbag.

      • When separating the glass, take care not to damage the paint and interior/exterior ornaments.
      • To prevent the piano wire to be cut, do not cross it.
    3. Cut off the adhesive by pulling the piano wire around it.
      Fig 3: Identifying Areas To Cut With Piano Wire
      G02823587Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using a suction rubber, remove the glass.
    NOTE: Leave as much adhesive on the body as possible when removing the glass.
  18. CLEAN WINDSHIELD GLASS 
    1. Using a scraper, remove the damaged stoppers, dam and adhesive sticking to the glass.
      Fig 4: Cleaning Windshield Glass
      G02823588Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Clean the outer circumference of the glass with white gasoline.
    CAUTION:
    • Do not touch the glass after cleaning it.
    • Be careful not to damage the body.
  19. INSTALL WINDSHIELD GLASS STOPPER NO. 1 
    1. Install 2 new windshield glass stoppers No. 1 to the body.
  20. INSTALL WINDSHIELD GLASS STOPPER NO. 2 
    1. Coat the installation part of the stopper with Primer G.
      NOTE:
      • Dry the primer coating dry for 3 minutes or more.
      • Do not apply too much primer.
    2. Install 2 new windshield glass stoppers No. 2 onto the glass as shown in Fig 5.
      Fig 5: Installing Windshield Glass Stopper No. 2
      G02823589Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      A: 7.7 mm (0.303 in.) 

      B: 40.0 mm (1.575 in.) 

  21. INSTALL WINDSHIELD GLASS RETAINER 
    1. Install 2 new windshield glass retainers onto the glass as shown in Fig 6.
      Fig 6: Installing Windshield Glass Retainers Onto Glass
      G02823590Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. INSTALL WINDOW GLASS ADHESIVE DAM 
    1. Coat the installation part of the window glass adhesive dam with Primer G.
      NOTE:
      • Let the primer coating dry for 3 minutes or more.
      • Do not apply too much primer.
    2. Install a new window glass adhesive dam as shown in Fig 7.
      Fig 7: Installing Window Glass Adhesive Dam
      G02823591Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      a: 7 mm (0.28 in.) 

      b: 35 mm (1.38 in.) 

  23. INSTALL WINDSHIELD GLASS 
    1. Clean and shape the contact surface of the vehicle's body
      1. Using a knife, cut away any rough adhesive on the contact surface of the body to shape the surface.
        Fig 8: Cleaning And Shaping Contact Surface Of Vehicle'S Body
        G02823592Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        NOTE: 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.
    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.
        NOTE: When reusing the glass, check and correct the reference mark's 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 apply too much Primer.
    4. Using a brush or sponge, coat the edge of the glass and the contact surface with Primer G.
      NOTE:

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

      CAUTION:
      • Dry the primer coating for 3 minutes or more.
      • Do not apply too much primer.
    5. Apply adhesive.
      1. Cut off the tip of the cartridge nozzle.

        Part No. 08850-00801 or equivalent 

        NOTE: After cutting off the tip, use all adhesive within the time described in ADHESIVE USAGE TIME .
        ADHESIVE USAGE 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 9.
        Fig 9: Appling Adhesive
        G02823593Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        a: 8 mm (0.31 in.) 

        b: 12 mm (0.47 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.
      2. Lightly press the glass front surface for close contact.
      3. Using a scraper, remove any excess or protruding adhesive.
      NOTE: Apply adhesive on the glass rim.
  24. INSTALL WINDSHIELD MOLDING OUTER UPPER 
    1. Install a new windshield molding to the windshield glass before the adhesive has hardened.
    2. Hold the windshield glass in place securely with protective tape or equivalent until the adhesive has completely hardened.
    3. Using a scraper, remove any excess or protruding adhesive before the adhesive has hardened.
    CAUTION: Take care not to drive the vehicle during the time described in VEHICLE DRIVING TIME .
    VEHICLE DRIVING TIME

    Temperature Tackfree Time
    35° C (95° F) 1.5 Hours
    20° C (68° F) 5 Hours
    5° C (41° F) 24 Hours
  25. WATER-LEAK CHECK AND REPAIR 
    1. Conduct a leak test after the adhesive has completely hardened.
    2. Seal any leak with sealant.
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