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 a standard bolt.

REMOVE FR WIPER ARM RH (See REPLACEMENT )
REMOVE FR WIPER ARM LH (See REPLACEMENT )
REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSY (See REPLACEMENT )
REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP RH (See REPLACEMENT )
REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP LH (See REPLACEMENT )
REMOVE FRONT PILLAR GARNISH RH (w/o CURTAIN SHIELD AIR BAG) (See REPLACEMENT )
REMOVE FRONT PILLAR GARNISH LH (w/o CURTAIN SHIELD AIR BAG) (See REPLACEMENT )
REMOVE FRONT PILLAR GARNISH RH (w/ CURTAIN SHIELD AIR BAG) (See REPLACEMENT )
REMOVE FRONT PILLAR GARNISH LH (w/ CURTAIN SHIELD AIR BAG) (See REPLACEMENT )
REMOVE ROOF CONSOLE BOX ASSY (See REPLACEMENT )
REMOVE RH VISOR ASSY (See REPLACEMENT )
REMOVE LH VISOR ASSY (See REPLACEMENT )
REMOVE VISOR HOLDER (See REPLACEMENT )
REMOVE ROOF HEADLINING ASSY (See REPLACEMENT )
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 17.
REMOVE INNER REAR VIEW MIRROR ASSY (See REPLACEMENT )
REMOVE WINDSHIELD MOULDING OUTER UPPER
1. Using a knife, cut off the moulding, as shown in the illustration.
  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.

Fig 1: Removing Windshield Moulding Outer Upper
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE WINDSHIELD GLASS
HINT:

In some cases, 1-piece type and 2-piece type stoppers are installed in the same vehicle.

Fig 2: Removing Windshield Glass
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. From the interior, insert piano wires between the vehicle body and glass, as shown in the illustration.
2. Tie objects that can serve as handles (for example, wooden blocks) to all wire ends.
  
  Fig 3: Inserting Piano Wires Vehicle Body And Glass
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  Apply protective tape to the outer surface of the vehicle body to prevent its surface from being scratched.
  NOTE:
  - w/ Curtain shield airbag:
    When working around the curtain shield airbag, be careful not to damage the airbag.
  - When separating the glass from the vehicle, be careful not to damage the vehicle's paint or interior / exterior ornaments.
  - To prevent the safety pad from being scratched when removing the glass, place a plastic sheet between the piano wire and safety pad.
  Fig 4: Removing Glass
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Cut through the adhesive by pulling the piano wire around the glass.
4. Disengage the stoppers.
5. Using a suction cup, remove the glass.
NOTE: Leave as much adhesive on the vehicle 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 after cleaning it.
- Even if using new glass, clean the glass with white gasoline.
Fig 5: Removing Damaged Stoppers
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CLEAN VEHICLE BODY
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 vehicle body to ensure the appropriate surface shape.
    
    Fig 6: Cutting Rough Adhesive Contact Surface Vehicle Body
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    NOTE: Be careful not to damage the vehicle body.
    
    HINT:
    
    Leave as much adhesive on the vehicle body as possible.
  2. Clean the contact surface of the vehicle body with a piece of shop rag saturated with cleaner.
  HINT:
  
  Even if all the adhesive has been removed, clean the vehicle body.

INSTALL WINDSHIELD GLASS STOPPER NO.2

Coat the installation part of the stopper with Primer G.
NOTE:
- Allow the primer coating to dry for 3 minutes or more.
- Throw away any leftover Primer G.
- Do not apply too much Primer G.

Install 2 new stoppers onto the glass, as shown in the illustration.

Specification:

SPECIFICATION

Area	Measurement
A	7.7 mm (0.303 in.)
B	40.0 mm (1.575 in.)

Fig 7: Installing Windshield Glass Stopper

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL WINDSHIELD GLASS STOPPER NO.1
1. Install 2 new stoppers to the vehicle body, as shown in the illustration.
  
  Fig 8: Installing New Stoppers Vehicle Body
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL WINDSHIELD GLASS RETAINER
1. Install 2 new retainers onto the glass, as shown in the illustration.
  
  Fig 9: Installing Windshield Glass Retainer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL WINDOW GLASS ADHESIVE DAM

Coat the installation part of the windshield glass adhesive dam with Primer G.
NOTE:
- Allow the primer coating to dry for 3 minutes or more.
- Throw away any leftover Primer G.
- Do not apply too much primer.

Install a new dam, as shown in the illustration.

Specification:

SPECIFICATION

Area	Measurement
a	7.0 mm (0.276 in.)
b	35.0 mm (1.378 in.)

Fig 10: Installing Window Glass Adhesive Dam

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL WINDSHIELD GLASS

Position the glass.
1. Using a suction cup, 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 vehicle body.
  NOTE: Check that the stoppers are attached to the vehicle body correctly.
  
  HINT:
  
  When reusing the glass, check and correct the reference mark's positions.
4. Using a suction cup, remove the glass.
  
  Fig 11: Installing Windshield Glass
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using a brush, coat the exposed part of the vehicle body on the vehicle side with Primer M.
NOTE:
- Allow the primer coating to dry for 3 minutes or more.
- Do not coat the adhesive with Primer M.
- Throw away any leftover Primer M.
- Do not apply too much Primer M.
Using a brush or sponge, coat the edge of the glass and the contact surface with Primer G.
HINT:

If the area other than that specified is coated by accident, wipe off the primer with a clean shop rag before it dries.
NOTE:
- Allow the primer coating to dry for 3 minutes or more.
- Throw away any leftover Primer G.
- Do not apply too much Primer G.
Fig 12: Coating Exposed Part Vehicle Body Vehicle Side With Primer M
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 the illustration.

HINT:

After cutting off the tip, use all adhesive within the time described in the table below.

Usage time frame:

USAGE TIME FRAME

Temperature	Usage Time frame
35°C(95°F)	15 minutes
20°C (68°F)	1 hour 40 minutes
5°C(41°F)	8 hours

Load the sealer gun with the cartridge.
Coat the glass with adhesive, as shown in the illustration.

Specification:

SPECIFICATION

Area	Measurement
a	8.0 mm (0.315 in.)
b	12.0 mm (0.472 in.)

Fig 13: Cutting Off Tip

Install the glass.

Using a suction cup, position the glass so that the reference marks are aligned. Press it in gently along the rim.
NOTE:
- Allow the primer coating to dry for 3 minutes or more.
- Check that the stoppers are attached to the vehicle body correctly.
- Check that the vehicle body and glass have a small gap between them.
Lightly press the front surface of the glass to ensure that the glass is securely fit to the vehicle body.

Fig 14: Installing Glass
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using a scraper, remove any excess or protruding adhesive.

HINT:

Apply adhesive on the glass rim.

NOTE: Do not drive the vehicle for the amount of time described in the table below.

Minimum time:

MINIMUM TIME

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

Fig 15: Removing Excess

INSTALL WINDSHIELD MOULDING OUTER UPPER
1. Using a brush or sponge, coat the edge of the glass and the contact surface with Primer G.
  NOTE:
  - Allow the primer coating to dry for 3 minutes or more.
  - Throw away any leftover Primer G.
  - Do not apply too much Primer G.
2. Install the moulding.
CHECK FOR LEAKS AND REPAIR
1. Conduct a leak test after the adhesive has completely hardened.
2. Seal any leaks with auto glass sealer.