Windshield: Service and Repair
WINDSHIELD GLASSREMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
2. REMOVE FRONT DOOR OPENING TRIM LH
a. Partially remove the front door opening trim weatherstrip LH so that the front pillar garnish LH can be removed.
3. REMOVE FRONT DOOR OPENING TRIM RH
HINT: Use the same procedures described for the LH side.
4. REMOVE FRONT PILLAR GARNISH LH
5. REMOVE FRONT PILLAR GARNISH RH
6. REMOVE INNER REAR VIEW MIRROR ASSEMBLY
7. REMOVE ROOM LIGHT ASSEMBLY
8. REMOVE ASSIST GRIP COVER
9. REMOVE ASSIST GRIP SUB-ASSEMBLY FRONT
10. REMOVE VISOR ASSEMBLY LH
11. REMOVE VISOR ASSEMBLY RH
12. REMOVE VISOR HOLDER
13. REMOVE ROOF HEADLINING ASSEMBLY
HINT: It is not necessary to completely remove the roof headlining. Slightly lower the front section of the roof headlining.
a. Partially remove the roof headlining
14. REMOVE FRONT WIPER ARM HEAD CAP
15. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH
16. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH
17. REMOVE FRONT FENDER TO COWL SIDE SEAL LH
18. REMOVE FRONT FENDER TO COWL SIDE SEAL RH
19. REMOVE NO. 2 WINDSHIELD MOULDING OUTSIDE LH
a. Remove the moulding with the clip and claw.
20. REMOVE NO. 2 WINDSHIELD MOULDING OUTSIDE RH
a. Remove the moulding with the clip and claw.
21. REMOVE NO. 2 WINDSHIELD OUTSIDE MOULDING FASTENER
a. Apply protective tape to the outer surface of the vehicle body to prevent scratches. Using a heat light, heat the moulding to 40 to 60 degrees C (104 to 140 degrees F).
NOTE: Do not heat the moulding excessively.
b. Tie both piano wire ends to wooden blocks or similar objects.
c. Cut the adhesive tape by pulling the piano wire as shown in the illustration.
d. Remove the 2 clips and moulding fastener.
22. REMOVE NO. 1 WINDSHIELD OUTSIDE MOULDING FASTENER
HINT: Use the same procedures described for the LH side.
23. REMOVE COWL TOP VENTILATOR LOUVER
24. REMOVE FRONT WINDOW MOULDING INNER CENTER
a. Using a knife, cut off the moulding as shown in the illustration.
NOTE: Be careful not to damage the vehicle body.
b. Remove the remaining moulding.
HINT: Make a partial cut in the moulding. Then pull and remove it by hand.
25. REMOVE WINDSHIELD GLASS
a. w/ Windshield Deicer:
Remove the clip and disconnect the connector.
b. Apply protective tape to the outer surface of the vehicle body to prevent scratches.
c. From the interior, insert a piano wire between the vehicle body and glass as shown in the illustration.
d. Tie objects that can serve as handles (for example, wooden blocks) to both wire ends.
NOTE:
- When separating the glass from the vehicle, be careful not to damage the vehicle's paint or interior/exterior ornaments.
- To prevent the instrument panel from being scratched when removing the glass, place a plastic sheet between the piano wire and instrument panel.
e. Place matchmarks over the glass and vehicle body on the locations indicated in the illustration.
HINT: Matchmarks do not need to be placed if not reusing the glass.
f. Cut through the adhesive by pulling the piano wire around the glass.
NOTE: Leave as much adhesive on the vehicle body as possible when cutting through the adhesive.
g. Disengage the stoppers.
h. Using suction cups, remove the glass.
26. CLEAN WINDSHIELD GLASS
a. Using a scraper, remove the damaged stoppers, dams and adhesive sticking to the glass.
b. Clean the outer edges of the glass with white gasoline.
NOTE: Do not touch the glass surface after cleaning it. Even if using new glass, clean it with white gasoline.
27. CLEAN VEHICLE BODY
a. Clean and shape the contact surface of the vehicle body.
1. On the contact surface of the vehicle body, use a knife to cut away excess adhesive as shown in the illustration.
HINT: Leave as much adhesive on the vehicle body as possible.
NOTE: Be careful not to damage the vehicle body.
b. Clean the contact surface of the vehicle body with cleaner.
HINT: Even if all the adhesive has been removed, clean the vehicle body.
INSTALLATION
1. INSTALL NO. 2 WINDSHIELD GLASS STOPPER
a. Apply Primer G to the glass where the spacers will be installed.
NOTE:
- Allow the primer to dry for 3 minutes or more.
- Throw away any leftover primer.
- Do not apply too much primer.
b. Install 2 new spacers onto the glass as shown in the illustration.
2. INSTALL NO. 1 WINDSHIELD GLASS STOPPER
a. Install 2 new stoppers to the vehicle body as shown in the illustration.
3. INSTALL WINDOW GLASS ADHESIVE DAM
a. Apply Primer G to the glass where the glass adhesive dams will be installed.
NOTE:
- Allow the primer to dry for 3 minutes or more.
- Throw away any leftover primer.
- Do not apply too much primer.
b. Remove the peeling paper from the adhesive part of the dam. Install the dam (adhesive side) to the glass (Primer G area), but exclude the spacer area A as shown in the illustration.
4. INSTALL FRONT WINDOW MOULDING INNER CENTER
a. Using a brush or sponge, coat the edge of the glass and the contact surface with Primer G.
NOTE:
- Allow the primer to dry for 3 minutes or more.
- Throw away any leftover primer.
- Do not apply too much primer.
b. Install the windshield outside moulding, as shown in the illustration.
NOTE: Do not drive the vehicle for the amount of time written in the table.
5. INSTALL WINDSHIELD GLASS
a. Position the glass.
1. Using suction cups, place the glass in the correct position.
2. Check that the entire contact surface of the glass rim is perfectly even.
3. Place matchmarks on the glass and vehicle body on the locations indicated in the illustration.
HINT:
- Placing matchmarks is only necessary when installing new glass. If it is the reused glass, matchmarks should already be present.
- When reusing the glass, check and correct the match mark positions.
NOTE: Check that the stoppers are attached to the vehicle body correctly.
4. Using suction cups, remove the glass.
b. Using a brush, apply Primer M to the exposed part of the vehicle body.
NOTE:
- Allow the primer to dry for 3 minutes or more.
- Do not apply primer to the adhesive.
- Throw away any leftover primer.
- Do not apply too much primer.
c. Using a brush or sponge, apply Primer G to the contact surface of the glass.
HINT: If the primer is applied to an area that is not specified, apply white gasoline to a clean cloth and wipe off the excess primer.
NOTE:
- Allow the primer to dry for 3 minutes or more.
- Throw away any leftover primer.
- Do not apply too much primer.
d. Apply adhesive to the glass.
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 written in the table.
2. Load the sealer gun with the cartridge.
3. Apply adhesive to the glass as shown in the illustration.
e. Install the glass to the vehicle body.
1. Using suction cups, position the glass so that the matchmarks are aligned. Press it in gently along the rim.
2. Lightly press the outer surface of the glass to ensure that it is securely fit to the vehicle body.
NOTE:
- Check that the stoppers are attached to the vehicle body correctly.
- Check that the vehicle body and glass have a small gap between them.
3. Hold the glass in place securely with protective tape or equivalent until the adhesive hardens.
f. w/ Windshield deicer:
Install the clip and connect the connector.
6. INSTALL COWL TOP VENTILATOR LOUVER
7. INSTALL NO. 2 WINDSHIELD OUTSIDE MOULDING FASTENER
a. Install the moulding fastener with the 2 clips and double-sided tape.
8. INSTALL NO. 1 WINDSHIELD OUTSIDE MOULDING FASTENER
a. Install the moulding fastener with the 2 clips and double-sided tape.
9. INSTALL NO. 2 WINDSHIELD MOULDING OUTSIDE LH
a. Install the moulding with claw and clip.
10. INSTALL NO. 2 WINDSHIELD MOULDING OUTSIDE RH
a. Install the moulding with claw and clip.
11. INSTALL FRONT FENDER TO COWL SIDE SEAL LH
12. INSTALL FRONT FENDER TO COWL SIDE SEAL RH
13. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH
14. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH
15. INSTALL FRONT WIPER ARM HEAD CAP
16. INSTALL ROOF HEAD LINING
a. Install the roof headlining
17. INSTALL VISOR HOLDER
18. INSTALL VISOR ASSEMBLY LH
19. INSTALL VISOR ASSEMBLY RH
20. INSTALL ASSIST GRIP SUB-ASSEMBLY
21. INSTALL ASSIST GRIP COVER
22. INSTALL ROOM LIGHT ASSEMBLY
23. INSTALL INNER REAR VIEW MIRROR ASSEMBLY
24. INSTALL FRONT PILLAR GARNISH LH
25. INSTALL FRONT PILLAR GARNISH RH
26. INSTALL FRONT DOOR OPENING TRIM LH
27. INSTALL FRONT DOOR OPENING TRIM RH
28. CHECK FOR LEAKS AND REPAIR
a. Conduct a leak test after the adhesive has completely hardened.
b. Seal any leaks with auto glass sealer.
29. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL