Windshield: Service and Repair

WINDSHIELD GLASS

Windshield Glass:

REMOVAL

1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. REMOVE FRONT WIPER ARM HEAD CAP
3. REMOVE FRONT WIPER ARM LH
4. REMOVE FRONT WIPER ARM RH
5. REMOVE FRONT FENDER TO COWL SIDE SEAL LH
6. REMOVE FRONT FENDER TO COWL SIDE SEAL RH

HINT: Follow the same procedures as for the fender to cowl side seal LH.

7. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY
8. REMOVE INNER REAR VIEW MIRROR ASSEMBLY
9. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP LH
a. Separate the front door opening trim weatherstrip to the extent which allows the removal of the front pillar garnish.

10. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP RH

HINT: Follow the same procedures as for the front door opening trim weatherstrip LH.

11. REMOVE FRONT PILLAR GARNISH LH (for Regular Cab)
12. REMOVE FRONT PILLAR GARNISH LH (for Access Cab)
13. REMOVE FRONT PILLAR GARNISH LH (for Double Cab)
14. REMOVE FRONT PILLAR GARNISH RH (for Regular Cab)

HINT: Follow the same procedures as for the front pillar garnish LH.

15. REMOVE FRONT PILLAR GARNISH RH (for Access Cab)

HINT: Follow the same procedures as for the front pillar garnish LH.

16. REMOVE FRONT PILLAR GARNISH RH (for Double Cab)

HINT: Follow the same procedures as for the front pillar garnish LH.

17. REMOVE ROOF CONSOLE BOX ASSEMBLY (for Access Cab)
18. REMOVE ROOF CONSOLE BOX ASSEMBLY (for Double Cab)
19. REMOVE ASSIST GRIP PLUG (w/ Curtain Shield Airbag)
20. REMOVE ASSIST GRIP SUB-ASSEMBLY (for Double Cab)
21. REMOVE VISOR ASSEMBLY LH (for Regular Cab)
22. REMOVE VISOR ASSEMBLY LH (for Access Cab)
23. REMOVE VISOR ASSEMBLY RH (for Double Cab)
24. REMOVE VISOR ASSEMBLY RH (for Regular Cab)

HINT: Follow the same procedures as for the LH visor.

25. REMOVE VISOR ASSEMBLY RH (for Access Cab)

HINT: Follow the same procedures as for the LH visor.

26. REMOVE VISOR ASSEMBLY RH (for Double Cab)

HINT: Follow the same procedures as for the LH visor.

27. REMOVE VISOR HOLDER (for Regular Cab)
28. REMOVE VISOR HOLDER (for Access Cab)
29. REMOVE VISOR HOLDER (for Double Cab)
30. REMOVE WINDSHIELD UPPER MOLDING OUTER

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

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

b. Remove the windshield upper moulding outer.

HINT: Make a partial cut in the windshield upper moulding outer. Then pull and remove it by hand.

31. REMOVE WINDSHIELD GLASS

a. Apply protective tape to the outer circumference of the windshield glass, as shown in the illustration.
b. From the interior, insert piano wires between the vehicle body and windshield glass, as shown in the illustration.
c. Tie objects that can serve as handles (for example, wooden blocks) to all wire ends.

NOTICE:
- When separating the windshield glass from the vehicle, be careful not to damage the vehicle's paint or exterior/interior 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.

d. Cut through the adhesive by pulling the piano wire around the windshield glass.

e. Disengage the 2 stoppers.
f. Using suction cups, remove the windshield glass.

NOTICE: Leave as much adhesive on the vehicle body as possible when removing the windshield glass.

INSTALLATION

1. CLEAN WINDSHIELD GLASS

a. Using a scraper, remove the damaged stoppers, dam and adhesive stuck to the windshield glass.
b. Clean the outer circumference of the windshield glass with white gasoline.

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

2. 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 shop rag saturated with cleaner.

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

3. INSTALL NO.2 WINDSHIELD GLASS STOPPER

a. Apply Primer G to the installation part of the stoppers.

NOTICE:
- Allow the primer to dry for 3 minutes or more.
- Throw away any leftover Primer G.
- Do not apply too much Primer G.

b. Install 2 new stoppers onto the windshield glass, as shown in the illustration.

4. INSTALL NO.1 WINDSHIELD GLASS STOPPER

a. Install 2 new stoppers onto the vehicle body, as shown in the illustration.

5. INSTALL WINDSHIELD GLASS ADHESIVE DAM
a. Apply Primer G to the illustration part of the dam.

NOTICE:
- Allow the primer to dry for 3 minutes or more.
- Throw away any leftover Primer G.
- Do not apply too much Primer G.

b. Install 3 new dams. Install the 3 new dams by applying double-sided tape all the way around the windshield glass except where the stoppers are installed, as shown in the illustration.

6. INSTALL WINDSHIELD GLASS

a. Position the windshield glass.
1. Using suction cups, place the windshield glass in the correct position.
2. Check that the whole contact surface of the windshield glass rim is perfectly even.
3. Place matchmarks over the windshield glass and vehicle body.

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

HINT: When reusing the windshield glass, check and correct the matchmark positions.

4. Using suction cups, remove the windshield 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 M to the adhesive.
- Throw away any leftover Primer M.
- Do not apply too much Primer M.

c. Using a brush or sponge, apply Primer G to the edge of the windshield glass and contact surface.

NOTICE:
- Allow the primer to dry for 3 minutes or more.
- Throw away any leftover Primer G.
- Do not apply too much Primer G.

HINT: If Primer G is applied to any areas other than that which is specified, wipe off the primer with a clean shop rag before it dries.

d. Apply adhesive.
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 times indicated in the table bellow.

2. Load the sealer gun with the cartridge.
3. Apply adhesive to the windshield glass as shown in the illustration.

e. Install the windshield glass onto the vehicle body.

1. Using suction cups, position the windshield glass so that the matchmarks are aligned. Press it in gently along the rim

NOTICE:
- Allow the primer to dry for 3 minutes or more.
- Check that the stoppers are attached to the vehicle body correctly.
- Check that the vehicle body and windshield glass have a small gap between them.

2. Lightly press the front surface of the windshield glass to ensure that the windshield glass is securely fitted to the vehicle body.

3. Using a scraper, remove any excessive or protruding adhesive.

HINT: Apply adhesive to the windshield glass rim.

7. INSTALL WINDSHIELD UPPER MOULDING OUTER

a. Using a brush or sponge, apply Primer G to the edge of the windshield glass and contact surface.

NOTICE:
- Allow the primer to dry for 3 minutes or more.
- Throw away any leftover Primer G.
- Do not apply too much Primer G.

b. Install the windshield upper moulding outer before the adhesive dries.

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

8. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY
9. INSTALL FRONT FENDER TO COWL SIDE SEAL LH
10. INSTALL FRONT FENDER TO COWL SIDE SEAL RH

HINT: Follow the same procedures as for the fender to cowl side seal LH.

11. INSTALL FRONT WIPER ARM LH
12. INSTALL FRONT WIPER ARM RH
13. INSTALL FRONT WIPER ARM HEAD CAP
14. CHECK FOR LEAKAGE AND REPAIR
a. Conduct a leak test after the adhesive has completely hardened.
b. Seal any leakage with auto glass sealer.

15. INSTALL VISOR HOLDER (for Regular Cab)
16. INSTALL VISOR HOLDER (for Access Cab)
17. INSTALL VISOR HOLDER (for Double Cab)
18. INSTALL VISOR ASSEMBLY LH (for Regular Cab)
19. INSTALL VISOR ASSEMBLY LH (for Access Cab)
20. INSTALL VISOR ASSEMBLY LH (for Double Cab)
21. INSTALL VISOR ASSEMBLY RH (for Regular Cab)

HINT: Follow the same procedures as for the LH visor.

22. REMOVE VISOR ASSEMBLY RH (for Access Cab)

HINT: Follow the same procedures as for the LH visor.

23. REMOVE VISOR ASSEMBLY RH (for Double Cab)

HINT: Follow the same procedures as for the LH visor.

24. INSTALL ASSIST GRIP PLUG (w/ Curtain Shield Airbag)
25. INSTALL ASSIST GRIP SUB-ASSEMBLY (for Double Cab)
26. INSTALL ROOF CONSOLE BOX ASSEMBLY (for Access Cab)
27. INSTALL ROOF CONSOLE BOX ASSEMBLY (for Double Cab)
28. INSTALL FRONT PILLAR GARNISH LH (for Regular Cab)
29. INSTALL FRONT PILLAR GARNISH LH (for Access Cab)
30. INSTALL FRONT PILLAR GARNISH LH (for Double Cab)

HINT: Follow the same procedures as for the front pillar garnish LH.

32. REMOVE FRONT PILLAR GARNISH RH (for Access Cab)

HINT: Follow the same procedures as for the front pillar garnish LH.

33. REMOVE FRONT PILLAR GARNISH RH (for Double Cab)

HINT: Follow the same procedures as for the front pillar garnish LH.

34. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP LH
a. Install the front door opening trim weatherstrip.

35. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP RH

HINT: Follow the same procedures as for the front opening trim weatherstrip LH.

36. INSTALL INNER REAR VIEW MIRROR ASSEMBLY
37. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Torque: 3.9 N.m (40 kgf.cm, 35 in.lbf)