Windshield: Service and Repair

WINDSHIELD GLASS

Windshield Glass:

Windshield Glass:

REMOVAL

HINT:
- Use the same procedures for the LH side and RH side.
- The procedures listed below are for the LH side.

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 ASSIST GRIP SUB-ASSEMBLY
a. Using a screwdriver, remove the 8 assist grip plugs, and then remove the 8 screws and 4 assist grips.

HINT: Tape the screwdriver tip before use.

3. REMOVE FRONT PILLAR GARNISH





a. Using a screwdriver, remove the garnishes.

HINT: Tape the screwdriver tip before use.

4. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP
5. REMOVE VISOR ASSEMBLY
a. Using a screwdriver, remove the 2 caps.

HINT: Tape the screwdriver tip before use.

b. Remove the 4 screws, and then disconnect the 2 connectors.
c. Remove the 2 visors.

6. REMOVE CENTER VISOR ASSEMBLY
a. Remove the 4 screws and 2 visors.

7. REMOVE VISOR HOLDER
a. Remove the 2 screws and 2 holders.

8. REMOVE OVERHEAD CONSOLE BOX





a. Remove the bolt.
b. Using a screwdriver, remove the console box, and then disconnect the connector.

HINT: Tape the screwdriver tip before use.

9. REMOVE OVERHEAD CONSOLE BOX (w/ LEXUS Link System)





a. Using a screwdriver, remove the switch assembly.





b. Remove the bolt.
c. Using a screwdriver, remove the console box, and then disconnect the connector.

HINT: Tape the screwdriver tip before use.

10. REMOVE INNER REAR VIEW MIRROR ASSEMBLY





a. Disconnect the connector.
b. Loosen the screw indicated by the arrow, and then remove the other screw and mirror.

11. REMOVE ROOF HEADLINING ASSEMBLY
a. Slightly lower the front section of the roof headlining so that the windshield glass can be removed.

HINT: It is not necessary to completely remove the roof headlining.

12. REMOVE NIGHT VIEW CAMERA ASSEMBLY (w/ Night View System)





a. Remove the nut and night view camera cover.
b. Remove the rain sensor bracket and disconnect the connector.





c. Loosen the screw, and remove the camera by sliding it upward along the front glass.

13. REMOVE RAIN SENSOR





NOTICE: Unlock the rain sensor by pulling the stopper before removing it.





a. Disconnect the connector and remove the screw.
b. Remove the sensor by sliding it horizontally along the front glass.

14. REMOVE FRONT WIPER ARM HEAD CAP
15. REMOVE WIPER ARM
a. Remove the 2 head caps and 2 nuts.
b. Remove the 2 wiper arms.

16. REMOVE HOOD TO COWL TOP SEAL
17. REMOVE COWL TOP VENTILATOR LOUVER LH
18. REMOVE COWL TOP VENTILATOR LOUVER RH
19. REMOVE NO. 2 WINDSHIELD MOULDING OUTSIDE
a. Using a screwdriver, remove the moulding.

HINT: Tape the screwdriver tip before use.





b. Using a drill bit with a diameter of less than 4 mm (0.16 in.), drill out the rivet heads and remove the moulding.

NOTICE:
- Do not drill the rivet at an angle as this will cause damage to the drill and drill hole. Line up the drill and rivet, and carefully drill out the rivet head.
- Be careful as the cut rivet will be very hot.

c. Continue drilling and push out the remaining rivet fragments.
d. Using a heat light, heat the moulding to 40 to 60° C (104 to 140° F).

NOTICE: Do not heat the moulding excessively.

e. Tie both piano wire ends to wooden blocks or similar objects.





f. Cut the adhesive tape by pulling the piano wire as shown in the illustration.

NOTICE:
- If reusing the moulding, take care not to damage the moulding.
- Do not damage the body.

HINT: Apply protective tape to the outer surface to keep the surface from being scratched.

g. Remove the moulding.

20. REMOVE WINDSHIELD MOULDING OUTER UPPER





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

NOTICE: Be careful not to damage the body with the knife.

21. REMOVE WINDSHIELD GLASS





a. Push piano wire through between the body and glass from the interior.





b. Tie both wire ends to wooden blocks or similar objects.

HINT: Apply protective tape to the outer surface to keep the surface from being scratched.

NOTICE: When separating the glass, take care not to damage the paint and interior and exterior ornaments. To prevent scratching the safety pad when removing the windshield, place a plastic sheet between the piano wire and safety pad.

c. Cut the adhesive by pulling the piano wire around it.
d. Remove the windshield glass.

NOTICE: Leave as much adhesive on the body as possible when cutting the glass.

22. 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.

NOTICE: Do not touch the glass surface after cleaning it. Even if using a new glass, clean it with white gasoline.

23. 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.

NOTICE: Be careful not to damage the vehicle body.

2. Clean the contact surface of the vehicle body with cleaner.

HINT: Even if all the adhesive has been removed, clean the vehicle body.

INSTALLATION

HINT:
- Use the same procedures for the LH side and RH side.
- A bolt without a torque specification is shown in the standard bolt chart.

1. INSTALL WINDSHIELD GLASS STOPPER








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

2. INSTALL WINDSHIELD GLASS ADHESIVE DAM








a. Install new dams with adhesive tape as shown in the illustration.

NOTICE: Do not touch the glass surface after cleaning it.

3. INSTALL WINDSHIELD GLASS
a. Position the glass.





1. Using suction cups, place the glass in the correct position.
2. Place matchmarks on the glass and vehicle body on the locations indicated in the illustration.

HINT:
- Placing matchmarks is only necessary when installing a new glass. If it is the reused glass, matchmarks should already be present.
- When reusing the glass, check and correct the matchmark positions.

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

3. Using suction cups, remove the 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 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.

NOTICE:
- 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: Part No. 08850-00801 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 below.





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.

NOTICE:
- 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. Use a scraper to remove any excess or protruding adhesive.





HINT: Make sure that the dam is attached to the body panel, as shown in the illustration.

4. Hold the glass in place securely with protective tape or equivalent until the adhesive hardens.

NOTICE: Do not drive the vehicle for the amount of time written in the table below.





4. CHECK FOR LEAKS AND REPAIR
a. Conduct a leak test after the adhesive has completely hardened.
b. Seal any leaks with auto glass sealer.

Sealant: Part No. 08833-00030 or equivalent.

5. APPLY ADHESIVE TO MOULDING INSTALLATION AREA





a. Apply adhesive to the moulding installation area between the glass and body.

Sealant: Part No. 08833-00030 or equivalent.

6. INSTALL WINDSHIELD MOULDING OUTER UPPER





a. Place a new moulding onto the body and tap it by hand.

7. INSTALL NO. 2 WINDSHIELD MOULDING OUTSIDE





a. Using an air riveter with No. 4 nose piece, install 4 new rivets and the moulding.

HINT: Before using the air riveter with No. 4 nose piece, cut 5 mm (0.20 in.) at the edge of the No. 4 nose piece.

NOTICE:





- Do not prize a riveter. It could damage the riveter and cause loose fitting and mandrel bend.





- Do not tilt the riveter when fastening the rivet to the material to avoid loose fitting.
- Do not allow gap spacing between the rivet head and the material.





- Do not allow gap spacing between the rivet head and the material.

8. INSTALL COWL TOP VENTILATOR LOUVER LH
9. INSTALL COWL TOP VENTILATOR LOUVER RH
10. INSTALL HOOD TO COWL TOP SEAL
11. INSTALL FRONT WIPER ARM
12. INSTALL FRONT WIPER ARM HEAD CAP
13. INSTALL RAIN SENSOR
a. If reusing the sensor:
Install the new sensor tape.








1. Remove the used sensor tape from the windshield glass or sensor.
2. Stick new sensor tape on the lens surface of the sensor indicated by the hatched line.

NOTICE:
- Make sure that no dust or fingerprint is on the sheet surface.
- Stick the sheet so as not to come out from the placing face.

b. Install the rain sensor.

NOTICE:
- If reusing the windshield:
Check that no sensor tape remains on the windshield after removing the sensor. In case the tape remains, remove completely.
- Clean the glass surface with a cloth, etc.





1. Peel the peeling paper of the sensor tape.
2. Connect the connector and sensor with the screw.





3. Push the stopper.

HINT: Install the sensor harness so that it passes through a hole on the roof headlining.

14. INSTALL NIGHT VIEW CAMERA ASSEMBLY (w/ Night View System)





a. Install the camera by sliding it downward along the front glass, and then tighten the screw.

NOTICE: Install the camera wire as shown in the illustration.





b. Connect the connector.
c. Adjust the camera.





d. Install the night view cover with the nut.

NOTICE: Do not pinch the night view harness and rain sensor harness in the night view cover. Pass them through a hole on the side of the night view cover.

15. INSTALL INNER REAR VIEW MIRROR ASSEMBLY





a. Install the mirror with the 2 screws.
b. Connect the connector.

16. INSTALL ROOF HEADLINING ASSEMBLY
17. INSTALL OVERHEAD CONSOLE BOX





a. Connect the connector and console box.
b. Install the console box with the bolt.

18. INSTALL OVERHEAD CONSOLE BOX (w/ LEXUS Link System)





a. Connect the connector.
b. Install the console box with the bolt.
c. Attach the switch assembly.

19. INSTALL VISOR HOLDER
a. Install the 2 holders with the 2 screws.

20. INSTALL CENTER VISOR ASSEMBLY
a. Install the 2 visors with the 4 screws.

21. INSTALL VISOR ASSEMBLY
a. Install the 2 visors with the 4 screws, and then connect the 2 connectors.
b. Install the 2 caps.

22. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP
23. INSTALL FRONT PILLAR GARNISH
a. Install the 2 garnishes.

24. INSTALL ASSIST GRIP SUB-ASSEMBLY
a. Install the 4 assist grips with the 8 screws, and then install the 8 assist grip plugs.

25. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
26. PERFORM INITIALIZATION
a. Perform initialization.

NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.