Windshield: Service and Repair
WINDSHIELD GLASSWindshield Glass:
Windshield Glass:
REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH
3. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH
4. REMOVE FRONT FENDER TO COWL SIDE SEAL LH
5. REMOVE FRONT FENDER TO COWL SIDE SEAL RH
6. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY
7. REMOVE INNER REAR VIEW MIRROR ASSEMBLY
8. REMOVE RAIN SENSOR (w/ Rain Sensor)
9. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP LH
10. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP RH
11. REMOVE FRONT PILLAR GARNISH LH
12. REMOVE FRONT PILLAR GARNISH RH
13. REMOVE ROOF CONSOLE BOX ASSEMBLY
14. REMOVE VISOR ASSEMBLY LH
15. REMOVE VISOR ASSEMBLY RH
16. REMOVE VISOR HOLDER
17. REMOVE FRONT ASSIST GRIP SUB-ASSEMBLY
18. REMOVE ROOF HEADLINING ASSEMBLY
19. REMOVE WINDSHIELD MOULDING
a. Using a knife, cut off the moulding, as shown in the illustration.
NOTICE:
- Do not damage the vehicle body with the knife.
- If the vehicle body is damaged, repair the damaged portion by applying an anti-rust coating after removing the windshield glass.
b. Remove the remaining moulding from the windshield glass.
HINT: When removing the moulding, make a partial cut, then pull and remove it by hand.
20. REMOVE WINDSHIELD GLASS ASSEMBLY
a. Pass a piano wire between the vehicle body and glass from the interior.
b. Tie both wire ends to wooden blocks or similar objects.
c. Cut off the adhesive by pulling the piano wire around the windshield glass.
NOTICE:
- When separating the windshield glass, take care not to damage the paint or the interior and exterior ornaments.
- To prevent the safety pad from being scratched when removing the windshield glass, place a plastic sheet between the piano wire and safety pad.
d. Place matchmarks on the windshield glass and vehicle body on the locations indicated in the illustration.
HINT: Matchmarks do not need to be placed if the windshield glass is not going to be reused.
e. Using a suction cup, remove the windshield glass assembly.
NOTICE:
- Be careful not to drop the windshield glass.
- Leave as much adhesive on the vehicle body as possible when removing the windshield glass.
21. REMOVE WINDOW GLASS ADHESIVE DAM
a. Using a scraper, remove the adhesive dam.
NOTICE:
- Be careful not to damage the windshield glass.
- Be sure to replace the adhesive dam with a new one.
22. REMOVE NO. 2 WINDSHIELD GLASS STOPPER
a. Using a scraper, remove the 2 No. 2 stoppers.
NOTICE:
- Be careful not to damage the windshield glass.
- Be sure to replace the No. 2 stoppers with new ones.
23. REMOVE WINDSHIELD GLASS RETAINER
a. Using a scraper, remove the 2 retainers.
NOTICE:
- Be careful not to damage the windshield glass.
- Be sure to replace the retainer with a new one.
24. CLEAN WINDSHIELD GLASS
a. Using a scraper, remove the adhesive tape and adhesive sticking to the windshield glass.
NOTICE: Be careful not to damage the windshield glass.
b. Clean the outer circumference of the windshield glass with a non-residue solvent.
NOTICE:
- Do not touch the windshield glass surface after cleaning it.
- Even if using a new windshield glass, clean the windshield glass with a non-residue solvent.
25. CLEAN VEHICLE BODY
a. 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.
NOTICE: 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 cloth saturated with cleaner.
HINT: Even if all the adhesive has been removed, clean the vehicle body.
INSTALLATION
1. INSTALL WINDSHIELD GLASS STOPPER NO. 2
a. Coat the installation part of the stopper with Primer G.
NOTICE:
- Allow the primer coating to dry for 3 minutes or more.
- Do not keep any of the opened Primer G for later use.
- Do not apply too much primer.
b. Install 2 new windshield glass stoppers onto the glass, as shown in the illustration.
2. INSTALL NO. 1 WINDSHIELD GLASS STOPPER
a. Install 2 new No. 1 stoppers to the vehicle body, as shown in the illustration.
HINT: Only 2-piece type No. 1 stoppers are supplied. Use the 2-piece type stoppers even if a 1-piece type was used.
3. INSTALL WINDSHIELD MOULDING
a. Using a brush or sponge, coat the application area of moulding with Primer G.
NOTICE:
- Do not apply too much primer.
- Allow the primer coating to dry for 3 minutes or more.
- Do not keep any of the opened Primer G for later use.
4. INSTALL WINDOW GLASS ADHESIVE DAM
a. Using a brush or sponge, coat the application area of adhesive dam with Primer G.
NOTICE:
- Do not apply too much primer.
- Allow the primer coating to dry for 3 minutes or more.
- Do not keep any of the opened Primer G for later use.
HINT: If an area other than that specified is coated by accident, wipe off the primer with a clean piece of cloth before it dries.
b. Install a new adhesive dam onto the windshield glass, as shown in the illustration.
NOTICE: Install the new adhesive dam along the ceramic notches.
5. INSTALL WINDSHIELD GLASS ASSEMBLY
a. Position the windshield glass assembly.
1. Using a suction cup, place the windshield glass assembly in the correct position.
2. Check that the whole contact surface of the windshield glass rim is perfectly even.
3. Align the matchmarks on the windshield glass and vehicle body.
NOTICE: Check that the windshield glass stoppers are attached to the vehicle body correctly.
4. Remove the windshield glass assembly.
b. Using a brush, coat the installation surface on the vehicle body with Primer M.
NOTICE:
- Do not coat the adhesive with Primer M.
- Do not apply too much primer.
- Allow the primer coating to dry for 3 minutes or more.
- Do not keep any of the opened Primer M for later use.
HINT: If an area other than that specified is coated by accident, wipe off the primer with a clean piece of cloth before it dries.
c. Using a brush or sponge, coat the application area of adhesive with Primer G.
NOTICE:
- Do not apply too much primer.
- Allow the primer coating to dry for 3 minutes or more.
- Do not keep any of the opened Primer G for later use.
HINT:
- Apply Primer G onto the ceramic notches.
- If an area other than that specified is coated by accident, wipe off the primer with a clean piece of cloth before it dries.
d. Apply adhesive (Adhesive: TOYOTA genuine windshield glass adhesive or equivalent).
1. 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.
2. Load the sealer gun with cartridge.
3. Apply adhesive to the windshield glass, as shown in the illustration.
HINT: Apply adhesive onto the ceramic notches.
e. Install the windshield glass assembly.
1. Using a suction cup, position the windshield glass so that the matchmarks are aligned, and press it in gently along the rim.
NOTICE:
- Check that the windshield glass stoppers are attached to the vehicle body correctly.
- Check the clearance between the vehicle body and windshield glass.
2. Lightly press the front surface of the windshield glass to ensure a close fit.
HINT: Press the glass with force of 98 N (10 kgf, 22 lb) or more.
3. If necessary, use a scraper to correct the level or position of adhesive that has been applied.
HINT: Apply adhesive onto the windshield glass rim.
4. Hold the windshield glass using protective tape until the applied adhesive becomes hard.
NOTICE: Do not drive the vehicle for the time described in the table below.
6. CHECK FOR LEAKS AND REPAIR
a. After the adhesive has hardened, apply water from the outside of the vehicle. Check that no water leaks into the cabin.
b. If water leaks into the cabin, allow the water to dry and add adhesive.
c. Remove the protective tape.
7. INSTALL ROOF HEADLINING ASSEMBLY
8. INSTALL FRONT ASSIST GRIP SUB-ASSEMBLY
9. INSTALL VISOR HOLDER
10. INSTALL VISOR ASSEMBLY LH
11. INSTALL VISOR ASSEMBLY RH
12. INSTALL ROOF CONSOLE BOX ASSEMBLY
13. INSTALL FRONT PILLAR GARNISH LH
14. INSTALL FRONT PILLAR GARNISH RH
15. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP LH
16. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP RH
17. INSTALL INNER REAR VIEW MIRROR ASSEMBLY
18. INSTALL INNER REAR VIEW MIRROR STAY HOLDER COVER
19. INSTALL RAIN SENSOR (w/ Rain Sensor)
a. If reusing the rain sensor: Install the new rain sensor tape.
1. Remove the used rain sensor tape from the windshield glass or rain sensor.
2. Apply the new rain sensor tape on the lens surface of the rain sensor indicated by the hatched area.
NOTICE:
- Make sure that no dust or fingerprints are on the tape surface.
- Apply the tape securely.
b. Install the rain sensor.
NOTICE:
- If reusing the windshield:
Check that no rain sensor tape remains on the windshield after removing the rain sensor.
If tape remains, remove it.
- Clean the glass face with a shop rag, etc.
20. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY
21. INSTALL FRONT FENDER TO COWL SIDE SEAL RH
22. INSTALL FRONT FENDER TO COWL SIDE SEAL LH
23. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
24. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH
25. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH
26. INSPECT SRS WARNING LIGHT