Windshield: Service and Repair
WINDSHIELD GLASSWindshield Glass:
Windshield Glass:
REMOVAL
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 WIPER ARM LH
3. REMOVE FRONT WIPER ARM 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 FRONT DOOR OPENING TRIM WEATHERSTRIP LH
9. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP RH
10. REMOVE FRONT PILLAR GARNISH LH
11. REMOVE FRONT PILLAR GARNISH RH
12. REMOVE MAP LIGHT ASSEMBLY
13. REMOVE VISOR ASSEMBLY LH
14. REMOVE VISOR ASSEMBLY RH
15. REMOVE VISOR HOLDER
16. REMOVE ASSIST GRIP SUB-ASSEMBLY
17. REMOVE ROOF HEADLINING ASSEMBLY
18. REMOVE RAIN SENSOR (w/ Auto Wiper)
19. REMOVE WINDSHIELD MOULDING OUTSIDE
a. Using a knife, cut off the moulding, as shown in the illustration.
NOTICE: Do not damage the vehicle body with the knife.
b. Remove the remaining moulding from the vehicle body.
HINT: When removing, make a partial cut, then pull and remove it by hand.
c. Disconnect the connector as shown in the illustration (w/ Deicer).
20. REMOVE WINDSHIELD GLASS
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.
NOTICE:
- When separating the glass, take care not to damage the paint and the interior and exterior ornaments.
- To prevent the safety pad from being scratched when removing the glass, place a plastic sheet between the piano wire and safety pad.
HINT: Apply protective tape to the outer surface to prevent the surface from being scratched.
c. Cut off the adhesive by pulling the piano wire around the glass.
d. Disengage the stoppers.
e. Using a suction cup, remove the glass.
NOTICE: Leave as much adhesive on the vehicle body as possible when removing the glass.
21. REMOVE WINDSHIELD GLASS RETAINER
a. Remove the windshield glass retainer.
22. REMOVE WINDSHIELD GLASS NO.2 STOPPER
a. Using a scraper, remove the windshield glass No.2 stoppers.
23. REMOVE WINDSHIELD GLASS NO.1 STOPPER
a. Remove the windshield glass No.1 stoppers.
24. CLEAN WINDSHIELD GLASS
a. Using a scraper, remove the damaged stoppers, dam and adhesive sticking to the glass.
b. Clean the outer circumference of the glass with a non-residue solvent.
NOTICE:
- Do not touch the glass surface after cleaning it.
- Be careful not to damage the glass.
- Even if using a new glass, clean the glass with a non-residue solvent.
INSTALLATION
1. INSTALL WINDSHIELD GLASS NO.1 STOPPER
a. Install 2 new stoppers to the vehicle body, as shown in the illustration.
2. INSTALL WINDSHIELD GLASS NO.2 STOPPER
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.
3. INSTALL WINDSHIELD GLASS RETAINER
a. Install a new windshield glass retainer to the glass, as shown in the illustration.
4. INSTALL WINDOW GLASS ADHESIVE DAM
a. Coat the installation part of the dam with Primer G.
NOTICE:
- Allow the primer coating to dry for 3 minutes or more.
- Do not apply too much primer.
b. Install a new dam, applying double-sided tape all the way around the glass except where the dam is installed, as shown in the illustration.
5. INSTALL WINDOW GLASS NO.2 ADHESIVE DAM
6. INSTALL WINDSHIELD GLASS
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 shop rag saturated with cleaner.
HINT: Even if all the adhesive has been removed, clean the vehicle body.
b. Position the glass.
1. Using a suction cup, 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 vehicle body.
NOTICE: Check that the stoppers are attached to the vehicle body correctly.
HINT: When reusing the glass, check and correct the reference mark positions.
4. Remove the glass.
c. Using a brush, coat the exposed part of the vehicle body on the vehicle side with Primer M.
NOTICE:
- Allow the primer coating to dry for 3 minutes or more.
- Do not coat the adhesive with Primer M.
- Do not keep any of the opened Primer M for later use.
d. 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 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 shop rag before it dries.
e. 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 the cartridge.
3. Coat the glass with adhesive, as shown in the illustration.
f. Install the glass.
1. Using a suction cup, position the glass so that the reference marks are aligned, and press it in gently along the rim.
NOTICE:
- Allow the primer coating to dry for 3 minutes or more.
- Check that the stoppers are attached to the vehicle body correctly.
- Check the clearance between the vehicle body and glass.
2. Lightly press the front surface of the glass to ensure a close fit.
3. Using a scraper, remove any excess or protruding adhesive.
NOTICE: Take care not to drive the vehicle for the time described in the table below.
HINT: Apply adhesive onto the glass rim.
7. INSTALL WINDSHIELD MOULDING OUTSIDE
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
- Do not keep any of the opened Primer G for later use.
b. Install the windshield moulding.
8. CHECK FOR LEAKS AND REPAIR
a. Conduct a leak test after the adhesive has completely hardened.
b. Seal any leaks with auto glass sealer.
9. INSTALL RAIN SENSOR (w/ Auto Wiper)
10. INSTALL ROOF HEADLINING ASSEMBLY
11. INSTALL ASSIST GRIP SUB-ASSEMBLY
12. INSTALL VISOR HOLDER
13. INSTALL VISOR ASSEMBLY LH
14. INSTALL VISOR ASSEMBLY RH
15. INSTALL MAP LIGHT ASSEMBLY
16. INSTALL FRONT PILLAR GARNISH LH
17. INSTALL FRONT PILLAR GARNISH RH
18. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP LH
19. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP RH
20. INSTALL INNER REAR VIEW MIRROR ASSEMBLY
21. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY
22. INSTALL FRONT FENDER TO COWL SIDE SEAL LH
23. INSTALL FRONT FENDER TO COWL SIDE SEAL RH
24. INSTALL FRONT WIPER ARM LH
25. INSTALL FRONT WIPER ARM RH
26. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
27. PERFORM INITIALIZATION
NOTICE: Some systems need initialization when disconnecting the cable from the negative (-) battery terminal.