Windshield: Service and Repair

WINDSHIELD GLASS

Windshield Glass:

REMOVAL

1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. REMOVE WINDSHIELD WIPER ARM COVER
3. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH
4. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH (CENTER SIDE)
5. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH
6. REMOVE ROOF ANTENNA POLE SUB-ASSEMBLY
7. REMOVE ANTENNA ORNAMENT
8. REMOVE FRONT FENDER SIDE PANEL UPPER RH
9. REMOVE FRONT FENDER SIDE PANEL UPPER LH
10. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY
11. REMOVE COWL TOP VENTILATOR LOUVER RH
12. REMOVE COWL TOP VENTILATOR LOUVER LH
13. REMOVE FRONT DOOR SCUFF PLATE RH
14. REMOVE FRONT DOOR SCUFF PLATE LH
15. REMOVE REAR DOOR SCUFF PLATE RH
16. REMOVE REAR DOOR SCUFF PLATE LH
17. REMOVE FRONT FLOOR FOOTREST
18. REMOVE FOOTREST CLIP
19. REMOVE COWL SIDE TRIM BOARD RH
20. REMOVE COWL SIDE TRIM BOARD LH
21. REMOVE ROOF SIDE INNER GARNISH COVER RH
22. REMOVE ROOF SIDE INNER GARNISH COVER LH
23. REMOVE ROOF SIDE RAIL GARNISH RH
24. REMOVE ROOF SIDE RAIL GARNISH LH
25. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP RH
26. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP LH
27. REMOVE ASSIST GRIP PLUG
28. REMOVE ASSIST GRIP ASSEMBLY
29. REMOVE FRONT PILLAR GARNISH RH
30. REMOVE FRONT PILLAR GARNISH LH
31. REMOVE VISOR ASSEMBLY RH
32. REMOVE VISOR ASSEMBLY LH
33. REMOVE VISOR HOLDER
34. REMOVE INNER REAR VIEW MIRROR STAY HOLDER COVER
35. REMOVE INNER REAR VIEW MIRROR ASSEMBLY
36. REMOVE ROOM LIGHT ASSEMBLY
37. REMOVE ROOF HEADLINING

HINT: It is not necessary to remove the roof headlining completely. Slightly lower the front section of the roof headlining.

38. REMOVE WINDSHIELD OUTSIDE UPPER MOULDING SUB-ASSEMBLY
39. REMOVE ROOF DRIP SIDE FINISH MOULDING RETAINER
40. REMOVE FRONT PILLAR OUTER GARNISH
41. REMOVE ROOF SIDE GARNISH PROTECTOR
42. REMOVE WINDSHIELD OUTSIDE LOWER MOULDING

a. Apply protective tape to the outer circumference of the windshield glass, as shown in the illustration.

b. Disengage the 6 claws and remove the windshield outside lower moulding.

43. REMOVE WINDSHIELD OUTSIDE MOULDING

a. Using a knife, cut off the windshield outside moulding, as shown in the illustration.

NOTICE: Do not damage the vehicle body with the knife.

b. Remove the windshield outside moulding.

HINT: Make a partial cut in the windshield outside moulding. Then pull and remove it by hand.

44. REMOVE WINDSHIELD GLASS

a. Apply protective tape to the outer circumference of the windshield glass, as shown in the illustration.
b. From the interior, insert piano wires between the vehicle body and the windshield glass, as shown in the illustration.
c. Tie objects that can serve as handles (for example, wooden blocks) to all wire ends.

NOTICE:
- When separating the windshield glass from the vehicle, do not damage the vehicle's paintwork or exterior/interior 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 in the locations indicated in the illustration.

HINT: Matchmarks do not need to be placed unless the windshield glass is going to be reused.

e. Cut through the adhesive by pulling the piano wire around the windshield glass.

f. Disengage the 2 stoppers.
g. Using suction cups, remove the windshield glass.

NOTICE: Leave as much adhesive on the vehicle body as possible when removing the windshield glass.

INSTALLATION

1. CLEAN WINDSHIELD GLASS

a. Using a scraper, remove the damaged stoppers, dam and adhesive from 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.

2. 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: Do not 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 shop rag or piece of cloth saturated with cleaner.

HINT: Clean the vehicle body even if all the adhesive has been removed.

3. INSTALL WINDSHIELD GLASS STOPPER NO. 1

a. Install 2 new stoppers onto the vehicle body, as shown in the illustration.

4. INSTALL WINDSHIELD GLASS STOPPER NO. 2

a. Apply Primer G to the installation parts of the stoppers.

NOTICE:
- Allow the primer to dry for 3 minutes or more.
- Throw away any leftover Primer G.
- Do not apply too much Primer G.

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

5. INSTALL WINDSHIELD OUTSIDE MOULDING

a. Using a brush or sponge, coat the edge of the glass and the contact surface with Primer G.

NOTICE:
- Allow the primer coating to dry for 3 minutes or more.
- Do not coat the adhesive with Primer G.
- Throw away any leftover Primer G.

b. Install the moulding onto the windshield glass, as shown in the illustration.

6. INSTALL WINDOW GLASS ADHESIVE DAM
a. Apply Primer G to the installation parts of new dams.

NOTICE:
- Allow the primer to dry for 3 minutes or more.
- Throw away any leftover Primer G.
- Do not apply too much Primer G.

b. Install 3 new dams by applying double-sided tape all the way around the windshield glass except where the stoppers are installed, as shown in the illustration.

7. INSTALL WINDSHIELD GLASS

a. Position the windshield glass.
1. Using suction cups, place the windshield glass in the correct position.
2. Check that the entire contact surface of the windshield glass rim is perfectly even.
3. Place matchmarks on the windshield glass and vehicle body.

NOTICE: Check that the stoppers are correctly attached to the vehicle body.

HINT: When reusing a windshield glass, check and correct the matchmarks positions.

4. Using suction cups, remove the windshield glass.

b. Using a brush, apply Primer M to the exposed part of the vehicle body.

NOTICE:
- Allow the primer to dry for 3 minutes or more.
- Do not apply Primer M to the adhesive.
- Throw away any leftover Primer M.
- Do not apply too much Primer M.

c. Using a brush or sponge, apply Primer G to the edge of the windshield glass and the contact surface.

NOTICE:
- Allow the primer to dry for 3 minutes or more.
- Throw away any leftover Primer G.
- Do not apply too much Primer G.

HINT: If Primer G is applied to any areas other than those specified, wipe off the primer with a clean shop rag or piece of cloth before it dries.

d. Apply adhesive.
Adhesive: Toyota Genuine Windshield Glass Adhesive or the equivalent

1. Cut the tip off the cartridge nozzle, as shown in the illustration.

HINT: After cutting off the tip, use all adhesive within the times indicated in the table below.

2. Load the sealer gun with the cartridge.
3 Apply adhesive to the windshield glass, as shown in the illustration.

e. Install the windshield glass onto the vehicle body.

1. Using suction cups, position the windshield glass so that the matchmarks are aligned. Gently press it in along the rim.

NOTICE:
- Allow the primer to dry for 3 minutes or more.
- Check that the stoppers are attached to the vehicle body correctly.
- Check that there is a small gap between the vehicle body and the windshield glass.

2. Gently press the front surface of the windshield glass to ensure that the windshield glass is securely fitted to the vehicle body.

3. Using a scraper, remove any excessive or protruding adhesive.

HINT: Apply adhesive to the windshield glass rim.

NOTICE: Do not drive the vehicle within the time indicated in the table below.

8. INSTALL WINDSHIELD OUTSIDE LOWER MOULDING

a. Engage the 6 claws and install the windshield outside lower moulding.

9. CHECK FOR LEAKAGE AND REPAIR
a. Conduct a leak test by applying water to the adhesive portions after the adhesive has completely hardened.
b. Seal any leakage with auto glass sealer.

10. INSTALL ROOF SIDE GARNISH PROTECTOR
11. INSTALL FRONT PILLAR OUTER GARNISH
12. INSTALL ROOF DRIP SIDE FINISH MOULDING RETAINER
13. INSTALL WINDSHIELD OUTSIDE UPPER MOULDING SUB-ASSEMBLY
14. INSTALL ROOF HEADLINING
15. INSTALL ROOM LIGHT ASSEMBLY
16. INSTALL INNER REAR VIEW MIRROR ASSEMBLY
17. INSTALL INNER REAR VIEW MIRROR STAY HOLDER COVER
18. INSTALL VISOR HOLDER
19. INSTALL VISOR ASSEMBLY RH
20. INSTALL VISOR ASSEMBLY LH
21. INSTALL FRONT PILLAR GARNISH RH
22. INSTALL FRONT PILLAR GARNISH LH
23. INSTALL ASSIST GRIP ASSEMBLY
24. INSTALL ASSIST GRIP PLUG
25. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP RH
26. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP LH
27. INSTALL ROOF SIDE RAIL GARNISH RH
28. INSTALL ROOF SIDE RAIL GARNISH LH
29. INSTALL ROOF SIDE INNER GARNISH COVER RH
30. INSTALL ROOF SIDE INNER GARNISH COVER LH
31. INSTALL COWL SIDE TRIM BOARD RH
32. INSTALL COWL SIDE TRIM BOARD LH
33. INSTALL FOOTREST CLIP
34. INSTALL FRONT FLOOR FOOTREST
35. INSTALL REAR DOOR SCUFF PLATE RH
36. INSTALL REAR DOOR SCUFF PLATE LH
37. INSTALL FRONT DOOR SCUFF PLATE RH
38. INSTALL FRONT DOOR SCUFF PLATE LH
39. INSTALL COWL TOP VENTILATOR LOUVER LH
40. INSTALL COWL TOP VENTILATOR LOUVER RH
41. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY
42. INSTALL FRONT FENDER SIDE PANEL UPPER LH
43. INSTALL FRONT FENDER SIDE PANEL UPPER RH
44. INSTALL ANTENNA ORNAMENT
45. INSTALL ROOF ANTENNA POLE SUB-ASSEMBLY
46. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH
47. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH (CENTER SIDE)
48. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH
49. INSTALL WINDSHIELD WIPER ARM COVER
50. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Torque: 3.9 N.m (40 kgf.cm, 35 in.lbf)