Windshield: Service and Repair

WINDSHIELD GLASS

Windshield 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 (for TMC Made without EC Mirror)
8. REMOVE INNER REAR VIEW MIRROR ASSEMBLY (for TMMK Made without EC Mirror)
9. REMOVE INNER REAR VIEW MIRROR STAY HOLDER COVER (w/ EC Mirror)
10. REMOVE INNER REAR VIEW MIRROR ASSEMBLY (w/ EC Mirror)
11. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP LH
12. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP RH
13. REMOVE FRONT PILLAR GARNISH LH
14. REMOVE FRONT PILLAR GARNISH RH
15. REMOVE ROOF CONSOLE BOX ASSEMBLY
16. REMOVE VISOR ASSEMBLY LH
17. REMOVE VISOR ASSEMBLY RH
18. REMOVE VISOR HOLDER
19. REMOVE FRONT ASSIST GRIP SUB-ASSEMBLY
20. REMOVE ROOF HEADLINING ASSEMBLY (w/o Sliding Roof)
It is not necessary to completely remove the roof headlining assembly. Slightly lower the front section of the roof headlining assembly so that the windshield glass can be removed.

21. REMOVE ROOF HEADLINING ASSEMBLY (w/ Sliding Roof)
It is not necessary to completely remove the roof headlining assembly. Slightly lower the front section of the roof headlining assembly so that the windshield glass can be removed.

22. 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.

23. REMOVE WINDSHIELD GLASS ASSEMBLY

NOTICE:
- There are No. 1 and No. 2 stoppers on the windshield glass as shown in the illustration. Be careful not to damage the windshield glass when cutting off the adhesive.
- To prevent the windshield glass from dropping when performing this operation, be sure to hold the windshield glass using suction cups.

HINT: Depending on vehicles, a 1-piece or 2-piece type stopper is used.






a. Apply protective tape to the installation position of the windshield glass assembly on the vehicle body.






HINT: Apply protective tape to the installation surface to prevent it from being scratched.

b. Pass a piano wire between the vehicle body and glass from the interior.






c. Tie both wire ends to wooden blocks or similar objects.
d. 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.

e. 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.

f. 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.

24. 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.

25. 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.

26. 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.

27. REMOVE NO. 1 WINDSHIELD GLASS STOPPER (for 2-piece Type)






a. Remove the 2 No. 1 stoppers.

NOTICE: Be sure to replace the No. 1 stoppers with new ones.

28. 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.

29. 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 NO. 2 WINDSHIELD GLASS STOPPER
a. Using a brush or sponge, coat the application area of the No. 2 stoppers 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 2 new No. 2 stoppers onto the windshield glass, 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.






2. INSTALL WINDSHIELD GLASS RETAINER
a. Using a brush or sponge, coat the application area of the retainers 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 2 new retainers onto the windshield glass, as shown in the illustration.






3. 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.

4. 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.

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 moulding, as shown in the illustration.






5. 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.






6. 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.






7. 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.

8. INSTALL ROOF HEADLINING ASSEMBLY (w/o Sliding Roof)
9. INSTALL ROOF HEADLINING ASSEMBLY (w/ Sliding Roof)
10. INSTALL FRONT ASSIST GRIP SUB-ASSEMBLY
11. INSTALL VISOR HOLDER
12. INSTALL VISOR ASSEMBLY LH
13. INSTALL VISOR ASSEMBLY RH
14. INSTALL ROOF CONSOLE BOX ASSEMBLY
15. INSTALL FRONT PILLAR GARNISH LH
16. INSTALL FRONT PILLAR GARNISH RH
17. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP LH
18. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP RH
19. INSTALL INNER REAR VIEW MIRROR ASSEMBLY (for TMC Made without EC Mirror)
20. INSTALL INNER REAR VIEW MIRROR ASSEMBLY (for TMMK Made without EC Mirror)
21. INSTALL INNER REAR VIEW MIRROR ASSEMBLY (w/ EC Mirror)
22. INSTALL INNER REAR VIEW MIRROR STAY HOLDER COVER (w/ EC Mirror)
23. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY
24. INSTALL FRONT FENDER TO COWL SIDE SEAL RH
25. INSTALL FRONT FENDER TO COWL SIDE SEAL LH
26. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
27. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH
28. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH
29. INSPECT SRS WARNING LIGHT