Windshield: Service and Repair

WINDSHIELD GLASS

Windshield Glass:

REMOVAL

1. REMOVE COOL AIR INTAKE DUCT SEAL
2. REMOVE HOOD HINGE COVER (for LH Side)
3. REMOVE HOOD HINGE COVER (for RH Side)
4. REMOVE ENGINE ROOM SIDE COVER LH
5. REMOVE ENGINE ROOM SIDE COVER RH
6. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH
7. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH
8. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

NOTICE: When removing the cowl top ventilator louver sub-assembly, hold the front fender to cowl side seals by hand to prevent them from coming off the windshield. The front fender to cowl side seals are attached to the windshield with double-sided tape. Once the front fender to cowl side seals come off, the adhesion of the tape is reduced. The double-sided tape is not available as a supply part. If the tape loses its adhesion, it is necessary to apply new high-heat resistant double-sided tape and install the front fender to cowl side seals to the windshield.

9. REMOVE SLIDING ROOF SIDE GARNISH LH (for Glass Roof)
10. REMOVE SLIDING ROOF SIDE GARNISH RH (for Glass Roof)
11. REMOVE NO. 1 SLIDING ROOF GLASS SUB-ASSEMBLY (for Glass Roof)
12. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
13. REMOVE INNER REAR VIEW MIRROR STAY HOLDER COVER
14. REMOVE INNER REAR VIEW MIRROR ASSEMBLY
15. REMOVE RAIN SENSOR COVER (w/ Rain Sensor)
16. REMOVE RAIN SENSOR (w/ Rain Sensor)
17. REMOVE RAIN SENSOR TAPE (w/ Rain Sensor)

HINT: This step should be performed only when the rain sensor tape needs to be replaced

18. REMOVE FRONT DOOR SCUFF PLATE LH
19. REMOVE FRONT DOOR OPENING TRIM COVER LH
20. REMOVE SIDE INSTRUMENT PANEL LH
21. REMOVE FRONT PILLAR GARNISH LH
22. REMOVE FRONT DOOR SCUFF PLATE RH
23. REMOVE FRONT DOOR OPENING TRIM COVER RH
24. REMOVE SIDE INSTRUMENT PANEL RH
25. REMOVE FRONT PILLAR GARNISH RH
26. REMOVE ROOF CONSOLE BOX ASSEMBLY
27. REMOVE VISOR BRACKET COVER
28. REMOVE VISOR ASSEMBLY LH
29. REMOVE VISOR ASSEMBLY RH
30. REMOVE VISOR HOLDER
31. REMOVE ASSIST GRIP SUB-ASSEMBLY
32. REMOVE ROOF HEADLINING ASSEMBLY (for Standard)
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.

33. REMOVE ROOF HEADLINING ASSEMBLY (for Glass 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.

34. REMOVE WINDSHIELD MOULDING OUTSIDE (for Standard)

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.

38. 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.

39. 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.

40. 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.

41. 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 retainers with new ones.

42. 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.

43. 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.

44. 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. 2 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 OUTSIDE (for Standard)
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 onto the windshield glass, as shown in the illustration.

5. INSTALL WINDSHIELD MOULDING OUTSIDE UPPER (for Glass Roof)
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 onto the windshield glass, as shown in the illustration.

6. INSTALL WINDSHIELD MOULDING OUTSIDE LH (for Glass Roof)
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 onto the windshield glass, as shown in the illustration.

7. INSTALL WINDSHIELD MOULDING OUTSIDE RH (for Glass Roof)

HINT: Use the same procedures for the RH side and LH side.

8. 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.

9. 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: 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.

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 applied adhesive becomes hard.

NOTICE: Do not drive the vehicle for the time described in the table below.

10. 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.

11. INSTALL ROOF HEADLINING ASSEMBLY (for Standard)
Return the front section of the roof headlining assembly to the original position

12. INSTALL ROOF HEADLINING ASSEMBLY (for Glass Roof)
Return the front section of the roof headlining assembly to the original position

13. INSTALL ASSIST GRIP SUB-ASSEMBLY
14. INSTALL VISOR HOLDER
15. INSTALL VISOR ASSEMBLY LH
16. INSTALL VISOR ASSEMBLY RH
17. INSTALL VISOR BRACKET COVER
18. INSTALL ROOF CONSOLE BOX ASSEMBLY
19. INSTALL FRONT PILLAR GARNISH LH
20. INSTALL SIDE INSTRUMENT PANEL LH
21. INSTALL FRONT DOOR OPENING TRIM COVER LH
22. INSTALL FRONT DOOR SCUFF PLATE LH
23. INSTALL FRONT PILLAR GARNISH RH
24. INSTALL SIDE INSTRUMENT PANEL RH
25. INSTALL FRONT DOOR OPENING TRIM COVER RH
26. INSTALL FRONT DOOR SCUFF PLATE RH
27. INSTALL RAIN SENSOR TAPE (w/ Rain Sensor)

HINT: This step should be performed only when the rain sensor tape needs to be replaced.

28. INSTALL RAIN SENSOR (w/ Rain Sensor)
29. INSTALL RAIN SENSOR COVER (w/ Rain Sensor)
30. INSTALL INNER REAR VIEW MIRROR ASSEMBLY
31. INSTALL INNER REAR VIEW MIRROR STAY HOLDER COVER
32. TEMPORARILY TIGHTEN NO. 1 SLIDING ROOF GLASS SUB-ASSEMBLY (for Glass Roof)
33. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
34. ADJUST NO. 1 SLIDING ROOF GLASS SUB-ASSEMBLY (for Glass Roof)
35. INSTALL SLIDING ROOF SIDE GARNISH LH (for Glass Roof)
36. INSTALL SLIDING ROOF SIDE GARNISH RH (for Glass Roof)
37. CHECK FOR WATER LEAKS (for Glass Roof)
38. INSTALL FRONT FENDER TO COWL SIDE SEAL RH

HINT: In cases where double-sided tape cannot be reused.

39. INSTALL FRONT FENDER TO COWL SIDE SEAL LH

HINT: In cases where double-sided tape cannot be reused.

40. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

NOTICE: When installing the cowl top ventilator louver sub-assembly, hold the front fender to cowl side seals by hand to prevent them from coming off the windshield. The front fender to cowl side seals are attached to the windshield with double-sided tape. Once the front fender to cowl side seals come off, the adhesion of the tape is reduced. The double-sided tape is not available as a supply part. If the tape loses its adhesion, it is necessary to apply new high-heat resistant double-sided tape and install the front fender to cowl side seals to the windshield

41. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH
42. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH
43. INSTALL ENGINE ROOM SIDE COVER RH
44. INSTALL ENGINE ROOM SIDE COVER LH
45. INSTALL HOOD HINGE COVER (for RH Side)
46. INSTALL HOOD HINGE COVER (for LH Side)
47. INSTALL COOL AIR INTAKE DUCT SEAL
48. PERFORM INITIALIZATION

NOTICE: Some systems need initialization after reconnecting the cable to the negative battery terminal.

49. CHECK SLIDING ROOF SYSTEM (for Glass Roof)
50. INSPECT SRS WARNING LIGHT