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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 FRONT PILLAR GARNISH RH (See step 33 under  REPLACEMENT  ) 
  2. REMOVE FRONT PILLAR GARNISH LH 
  3. REMOVE RH VISOR ASSY (See step 35 under  REPLACEMENT  ) 
  4. REMOVE LH VISOR ASSY 
  5. REMOVE VISOR HOLDER (See step 41 under  REPLACEMENT  ) 
  6. REMOVE COURTESY LENS (See step 37a under  REPLACEMENT
  7. REMOVE ROOF CONSOLE BOX ASSY (W/O SLIDING ROOF) (See step 37 under  REPLACEMENT  ) 
  8. REMOVE ROOF CONSOLE L/RELAY BOX ASSY (W/ SLIDING ROOF) (See step 37 under  REPLACEMENT  ) 
  9. REMOVE ASSIST GRIP SUB-ASSY (See step 40 under  REPLACEMENT  ) 
  10. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP LH 
  11. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP RH 
  12. REMOVE ROOF HEADLINING ASSY (See step 42 under  REPLACEMENT  ) 
    1. Remove the roof headlining assembly within the range that the window shield glass can be removed.
  13. REMOVE FR WIPER ARM RH (See  FR WIPER ARM RH  ) 
  14. REMOVE FR WIPER ARM LH (See  FR WIPER ARM LH  ) 
  15. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSY (See  COWL TOP VENTILATOR LOUVER SUB-ASSY  ) 
  16. REMOVE WINDSHIELD MOLDING OUTSIDE LH 
    1. Put protective tape.
    2. Using a screwdriver, remove the clip.
      3. Fig 1: Removing Windshield Molding Outside LH
      G02859629Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a screwdriver, remove the hooks and windshield molding outside LH.
  17. REMOVE WINDSHIELD MOLDING OUTSIDE RH 
  18. REMOVE WINDSHIELD OUTSIDE MOLDING CLIP NO. 1 
    1. Using a drill of less than 4 mm (0.16 in.), gently and vertically place the drill tip onto the rivet, and cut the rivet flanges.
      Fig 2: Cutting Rivet Flanges
      G02859630Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Wind the tape around the drill blade, so that the drill blade appears approx. 5.0 mm (0.20 in.) on the edge.
      CAUTION:
      • Prizing the hole with a drill can lead to damage to the rivet hole or the drill itself.
      • Be careful when undertaking this task as the cut rivet is hot.
    2. Even the if flange is taken off, continue drilling and push cut the remaining fragment with the drill.
    3. Remove the windshield outside molding clip No. 1.
  19. REMOVE WINDSHIELD MOLDING OUTER UPPER 
    1. Using a knife, cut off the windshield molding outer upper as shown inFig 3.
      Fig 3: Cutting Windshield Molding Outer Upper
      G02859631Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Do not damage the body with the knife.
  20. REMOVE INNER REAR VIEW MIRROR ASSY 
    1. Remove the inner rear view mirror assembly as shown in Fig 4.
      Fig 4: Removing Inner Rear View Mirror Assembly
      G02859632Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE WINDSHIELD GLASS 
    1. w/ window defogger Disconnect the connector.
    2. Pass a piano wire through between the body and glass from the interior.
      Fig 5: Disconnecting Window Defogger Connectors
      G02859633Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Tie both wire ends to wooden blocks or similar objects.
      Fig 6: Installing Piano Wire Between Body And Glass From Interior
      G02859634Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Apply protective tape to the outer surface to prevent the surface from being scratched.
      CAUTION:
      • When separating the glass, take care not to damage the paint, interior and exterior ornaments as shown in Fig 7.
      • To prevent scratching the safety pad when removing the windshield, place a plastic sheet between the piano wire and safety pad.
        • Fig 7: Cutting Adhesive By Pulling Piano Wire Around It
        G02859635Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Cut the adhesive by pulling the piano wire around it.
    5. Remove the glass.
      NOTE: Leave as much adhesive on the body as possible when cutting off the glass.
  22. CLEAN WINDSHIELD GLASS 
    1. Using a scraper, remove the damaged stoppers, dam and adhesive sticking to the glass.
      Fig 8: Cleaning Windshield Glass
      G02859636Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Clean the glass with cleaner or white gasoline.
    CAUTION:
    • Do not touch the glass after cleaning it.
    • Be careful not to damage the body.
  23. INSTALL WINDSHIELD GLASS STOPPER NO. 1 
    1. Install 2 new stoppers onto the glass as shown in Fig 9.
      Fig 9: Installing Stoppers Onto Windshield Glass
      G02859637Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      A: 9 mm (0.35 in.) 

  24. INSTALL WINDSHIELD GLASS STOPPER NO. 2 (W/ OUTER MIRROR HEATER) 
    1. Install 2 new stoppers No. 2 to the body as shown in Fig 10.
      2. Fig 10: Installing Windshield Glass Stopper No. 2
      G02859638Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. INSTALL WINDSHIELD GLASS STOPPER NO. 1 (W/ OUTER MIRROR HEATER) 
    1. Install 2 new stoppers onto the glass as shown in Fig 11.
      Fig 11: Installing Stoppers Onto Windshield Glass (W/Outer Mirror Heater)
      G02859639Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      A: 7 mm (0.28 in.) 

  26. INSTALL WINDOW GLASS ADHESIVE DAM 
    1. Install new window glass adhesive dam as shown in Fig 12.
      Fig 12: Installing New Window Glass Adhesive Dam
      G02859640Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      a: 7 mm (0.28 in.) 

      b: 37 mm (1.46 in.) 

  27. INSTALL WINDOW GLASS ADHESIVE DAM NO. 2 
  28. INSTALL WINDSHIELD GLASS 
    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 13: Identifying Adhesive On Contact Surface Of Body
        G02859641Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        NOTE: Leave as much of the adhesive on the body as possible.
      2. Clean the contact surface of the body with a piece of shop rag saturated with cleaner.
      NOTE: 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.
        Fig 14: Placing Glass In Correct Position
        G02859642Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        NOTE: Check that the stoppers are attached to the body correctly.
        When reusing the glass, check and correct the reference mark positions.
      4. Remove the glass.
    3. Coat the contact surface of the body with Primer M.
      1. Using a brush, coat the exposed part of body on the vehicle side with Primer M.
        Fig 15: Coating Contact Surface Of Body With Primer M
        G02859643Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Dry the primer coating dry for 3 minutes or more.
      • Do not apply Primer M onto the adhesive.
      • Do not keep any of the opened Primer M for later use.
    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
      NOTE:
      • Dry the primer coating for 3 minutes or more.
      • Do not keep any of the opened Primer G for later use.
    5. Apply adhesive.
      1. Cut off the tip of the cartridge nozzle, as shown in Fig 16.
        Fig 16: Cutting Off Tip Of Cartridge Nozzle And Applying Adhesive
        G02859644Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        part No. 08550-00801 or equivalent 

        NOTE: After cutting off the tip, use all adhesive within the time described in ADHESIVE APPLYING TACKFREE TIME AND TEMPERATURE .
        ADHESIVE APPLYING TACKFREE TIME AND TEMPERATURE

        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 16.

      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 lined up, and press it in gently along the rim.
        Fig 17: Installing Glass
        G02859645Courtesy 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.
      2. Lightly press the glass front surface for close contact.
      3. Using a scraper, remove any excess or protruding adhesive.
        Fig 18: Removing Excess Adhesive
        G02859646Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE: Apply adhesive on the glass rim.
    Fig 19: Applying Adhesive On Glass Rim
    G02859647Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    CAUTION: Take care not to drive the vehicle during the time described in ADHESIVE SPECIFICATIONS .
    ADHESIVE SPECIFICATIONS

    Temperature Minimum Time Prior To Driving The Vehicle
    35° C (95° F) 1.5 hours
    20° C (68° F) 5 hours
    5° C (41° F) 24 hours
  29. INSTALL WINDSHIELD MOLDING OUTER UPPER 
    1. Place a new molding onto the body and tap it by hand.
  30. WATER-LEAK CHECK AND REPAIR 
    1. Conduct a leak test after the hardening time has elapsed.
    2. Seal any leak with sealant.
  31. INSTALL WINDSHIELD OUTSIDE MOLDING CLIP NO. 1 
    1. Using an air riveter or hand riveter with nose piece, strike rivets into the body panel to install the windshield outside molding clip No. 1 to the body panel.
      Fig 20: Installing Windshield Outside Molding
      G02859648Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE:
    • If the rivet is not positioned perpendicularly it will bend the mandrel.
    • When trigger is then pulled, it may damage SST.
    NOTE:
    • Do not hold riveter at an angle because the riveter will be damaged and the mandrel will be bent.
      Fig 21: Identifying Wrong Installation Of Rivets (1 Of 3)
      G02859649Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    • Do not tilt the riveter when installing the rivet, because the materials are not tightened firmly.
      Fig 22: Identifying Wrong Installation Of Rivets (2 Of 3)
      G02859650Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    • Install the rivet while attaching the materials, because they are not tightened firmly.
      Fig 23: Identifying Wrong Installation Of Rivets (3 Of 3)
      G02859651Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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