Windshield: Service and Repair
REMOVAL1. REMOVE ASSIST GRIPS
a. Using a screwdriver, remove the 4 assist grip plugs, then remove the 4 screws and the 2 assist grips.
HINT: Tape up the screwdriver tip before use.
b. Use the same manner described above to the other side.
2. REMOVE FRONT PILLAR GARNISH
a. Using a screwdriver, remove the front pillar garnish.
HINT: Tape up the screwdriver tip before use.
b. Use the same manner described above to the other side.
3. REMOVE FRONT DOOR OPENING TRIMS
4. REMOVE SUN VISORS
a. Using a screwdriver, remove the 2 caps.
HINT: Tape up the screwdriver tip before use.
b. Remove the 4 screws, then disconnect the connectors.
c. Remove the 2 sun visors.
5. REMOVE DOUBLE VISORS
Remove the 4 screws and the 2 double visors.
6. REMOVE HOLDERS
Remove the 2 screws and the 2 holders.
7. REMOVE OVERHEAD CONSOLE BOX
a. Remove the bolt.
b. Using a screwdriver, remove the overhead console box, then disconnect the connector.
HINT: Tape up the screwdriver tip before use.
8. w/ LEXUS Link System:
REMOVE OVERHEAD CONSOLE BOX
a. Using a screwdriver, remove the LEXUS link system switch assembly.
HINT: Tape up the screwdriver tip before use.
b. Remove the bolt.
c. Using a screwdriver, remove the overhead console box, then disconnect the connectors.
HINT: Tape up the screwdriver tip before use.
9. REMOVE INNER REAR VIEW MIRROR
a. Disconnect the connector.
b. Unfasten a screw, and remove the other screw and the inner rear view mirror.
10. PULL DOWN FRONT PART OF ROOF HEADLINING
11. w/ Night View:
REMOVE NIGHT VIEW CAMERA
a. Remove the nut and night view cover.
b. Remove the rain sensor bracket and disconnect the connector.
c. Loosen the screw, and remove the night view camera by sliding it upward along the front glass.
12. REMOVE RAIN SENSOR
NOTE: Unlock the rain sensor by pulling the stopper before removing it.
a. Disconnect the connector and remove the screw.
b. Remove the rain sensor by sliding it horizontally along the front glass.
13. REMOVE WIPER ARMS
a. Remove the 2 wiper arm head caps and the 2 nuts.
b. Remove the 2 wiper arms.
14. REMOVE HOOD TO COWL TOP SEAL
15. REMOVE COWL TOP VENTILATOR LOUVERS
a. Remove the cowl top ventilator louver RH.
b. Remove the cowl top ventilator louver LH.
16. REMOVE OUTSIDE NO. 2 MOULDING
a. Using a screwdriver, remove the outside No. 2 moulding.
HINT: Tape up the screwdriver tip before use.
b. Using a drill of less then Dia 4 mm (0.16 in.).
c. Gently and vertically put the drill to the rivet, and cut the rivet flanges.
NOTE:
- Prizing the hole with a drill can lead to damage to the rivet hole or breaking the drill.
- Take cafe as the cut rivet is hot.
d. Even if the flange is taken off, continue drilling and push the out remaining fragments with the drill.
e. Using a heat light, heat the moulding to 40 - 60 degrees C (104 - 140 degrees F).
NOTE: Do not heat the moulding excessively.
f. Tie both piano wire ends to wooden blocks or similar objects.
g. Cut the adhesive tape by pulling the piano wire as shown.
NOTE:
- 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.
h. Remove the moulding.
i. Use the same manner described above to the other side.
17. REMOVE OUTSIDE UPPER MOULDING
Using a knife, cut off the moulding as shown in the illustration.
NOTE: Be careful not to damage the body with the knife.
18. REMOVE WINDSHIELD GLASS
a. Push piano wire through between the body and the 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.
NOTE: 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 the safety pad.
c. Cut the adhesive by pulling the piano wire around it.
d. Remove the windshield glass.
NOTE: Leave as much of the adhesive on the body as possible when cutting the glass.
INSTALLATION
1. CLEAN AND SHAPE CONTACT SURFACE OF BODY
a. Using a knife, cut away any rough areas on the body.
HINT: Leave as much of the adhesive on the body as possible.
b. Clean the cutting surface of the adhesive with a piece of shop rag soaked with cleanser.
2. CLEAN REMOVED GLASS
a. Remove the damaged stoppers and dams.
b. Using a scraper, remove the adhesive sticking to the glass.
c. Clean the glass with cleaner.
NOTE:
- Do not touch the glass surface after cleaning it.
- Be careful not to damage the glass.
3. INSTALL NEW STOPPERS
Install new stoppers onto the glass.
A: 9 mm (0.35 in.)
B: 25 mm (0.98 in.)
4. INSTALL NEW DAMS
Install new dams with adhesive tape as shown in the illustration.
NOTE: Do not touch the glass surface after cleaning it.
A: 7 mm (0.28 in.)
B: 20 mm (0.79 in.)
5. POSITION GLASS
a. Place the glass in the correct position.
b. Check that all contacting parts of the glass rim is perfectly even but does not contact with the 2 stoppers.
c. Place reference marks between the glass and the body.
d. Remove the glass.
6. CLEAN CONTACT SURFACE OF GLASS
Using cleanser, clean the contact surface which is black-colored area around the entire glass rim.
NOTE: Do not touch the glass surface after cleaning it.
7. COAT CONTACT SURFACE OF BODY WITH PRIMER "M"
Using a brush, coat Primer M to the exposed part of body on the vehicle side.
NOTE:
- Let the primer coating dry for 3 minutes or more.
- Do not coat Primer M to the adhesive.
- Do not keep the remaining Primer M for later use.
8. COAT CONTACT SURFACE OF GLASS WITH PRIMER "G"
a. Using a brush or sponge, coat the edge of the glass and the contact surface with Primer G.
b. If the primer is accidentally coated to the area not specified, wipe it off with a clean shop rag before the primer dries.
NOTE:
- Let the primer coating dry for 3 minutes or more.
- Do not keep the remaining Primer G for later use.
9. APPLY ADHESIVE
a. Cut off the tip of the cartridge nozzle.
Part No. 08850-00801 or equivalent.
HINT: After cutting off the tip, use all adhesive within the time described in the table.
b. Load the cartridge into the sealer gun.
c. Coat the glass with adhesive as shown.
A: 12.0 mm (0.472 in.)
B: 8.0 mm (0.315 in.)
10. INSTALL WINDSHIELD GLASS
a. Position the glass so that the reference marks are lined up and press in gently along the rim.
b. Using a spatula, apply adhesive on the glass rim.
c. 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.
d. Hold the windshield glass in place securely with a protective tape or equivalent until the adhesive hardens.
NOTE: Take care not to drive the vehicle with in the time described in the table.
11. INSPECT FOR LEAK AND REPAIR
a. Conduct a leak test after the hardening time elapsed.
b. Seal any leak with sealant.
Part No. 08833-00030 or equivalent.
12. APPLY ADHESIVE TO MOULDING INSTALLATION AREA
Apply adhesive to the moulding installation area between the glass and the body.
Part No. 08833-00030 or equivalent.
13. INSTALL UPPER OUTSIDE MOULDING
Place a new moulding onto the body and tap it by hand.
14. INSTALL OUTSIDE NO. 2 MOULDING
a. Using an air riveter with nose piece No. 4, install 4 new rivets and the outside No. 2 moulding.
HINT: Before using the air riveter with nose piece No. 4, cut 5 mm (0.20 in.) at the edge of nose piece No. 4.
NOTE:
- Do not prize a riveter. It could damage the riveter and cause loose fitting and mandrel bend.
- Do not tilt the riveter when fasten 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 materials.
b. Use the same manner described above to the other side.
15. INSTALL COWL TOP VENTILATOR LOUVERS
a. Install the cowl top ventilator louver LH.
b. Install the cowl top ventilator louver RH.
16. INSTALL HOOD TO COWL TOP SEAL
17. INSTALL WIPER ARMS
a. Operate the wiper motor once and turn the wiper switch OFF.
b. Install the wiper arms and tighten the nuts by hand.
c. Adjust the installation positions of the wiper arms to the positions as shown in the illustration.
A: Approx. 30 mm (1.18 in.)
B: Approx. 21 mm (0.83 in.)
d. Torque the nuts.
Torque: 20 N.m (204 kgf.cm, 15 ft.lbf)
e. Install the 2 wiper arm head caps.
18. INSTALL RAIN SENSOR
a. If reusing the rain sensor:
Install the new rain sensor tape.
1. Remove the used rain sensor tape from the windshield glass or rain sensor.
2. Stick new rain sensor tape on the lens surface of the rain sensor indicated by the hatched line.
A: 10 mm (0.39 in.)
NOTE:
- Make sure that no dust nor fingerprint is not on the sheet surface.
- Stick the sheet so as not come out from the placing face.
b. Install the rain sensor.
NOTE:
- If reusing the windshield:
Check that the no rain sensor tape remains on the windshield after removing the rain sensor. In case the tape remains, remove completely.
- Clean the glass surface with a cloth, etc.
1. Peel the separation paper of the rain sensor tape.
2. Connect the connector and the rain sensor with screw.
3. Push the stopper.
HINT: Install the rain sensor harness as it go through a hollow on the roof headlining.
19. w/ Night View:
INSTALL NIGHT VIEW CAMERA
a. Install the night view camera by sliding it downward along the front glass, and then tighten the screw.
NOTE: Install the night view camera assembly as shown on the illustration.
b. Connect the connector.
c. The adjustment of night view camera.
d. Install the night view cover and the nut.
NOTE: Do not pinch the night view harness and the rain sensor harness in the night view cover. Let them through a hole on the side of the night view cover.
20. INSTALL INNER REAR VIEW MIRROR
a. Install the inner rear view mirror with the 2 screw.
b. Connect the connector.
21. INSTALL FRONT PART OF ROOF HEADLINING
22. INSTALL OVERHEAD CONSOLE BOX
a. Connect the connector and the overhead console box.
b. Install the overhead console box with the bolt.
23. w/ LEXUS Link System:
INSTALL OVERHEAD CONSOLE BOX
a. Connect the connector and the overhead console box.
b. Install the overhead console box with bolt.
24. INSTALL HOLDERS
Install the 2 holders with the 2 screws.
25. INSTALL DOUBLE VISORS
Install the 2 double visors with the 4 screws.
26. INSTALL SUN VISORS
a. Install the 2 sun visors with the 4 screws, then connect the connectors.
b. Install the 2 caps.
27. INSTALL FRONT DOOR OPENING TRIMS
28. INSTALL FRONT PILLAR GARNISH
a. Install the front pillar garnish.
b. Use the same manner described above to the other side.
29. INSTALL ASSIST GRIPS
a. Install the 2 assist grips with the 4 screws, then install the 4 assist grip plugs.
b. Use the same manner described above to the other side.