Windshield: Service and Repair

WINDSHIELD GLASS

Windshield Glass:

Windshield Glass (Regular Cab):

Windshield Glass (Double Cab):

Windshield Glass (Double Cab, W/Short Type Roof Console Box):

Windshield Glass (Double Cab, W/Long Type Roof Console Box):

Windshield Glass:

REMOVAL

1. REMOVE FRONT SEAT ASSEMBLY (for Manual Seat)
a. Remove the front seat.

2. REMOVE FRONT SEAT ASSEMBLY (for Power Seat)
a. Remove the front seat.

3. REMOVE FRONT SEAT ASSEMBLY (for Center Seat)
a. Remove the front seat.

4. REMOVE REAR SEAT ASSEMBLY (for Double Cab)
a. Remove the rear seat.

5. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH
6. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH
7. REMOVE HOOD TO COWL TOP SEAL
8. REMOVE FRONT FENDER TO COWL SIDE SEAL LH
9. REMOVE FRONT FENDER TO COWL SIDE SEAL RH
10. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY
11. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP LH
a. Partially remove the front door opening trim weatherstrip LH so that the front pillar garnish LH can be removed.

12. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP RH

HINT: Use the same procedures described for the LH side.

13. REMOVE UPPER BACK PANEL GARNISH (for Regular Cab)
14. REMOVE LUGGAGE COMPARTMENT BOX LH (for Regular Cab)
15. REMOVE LUGGAGE COMPARTMENT BOX RH (for Regular Cab)
16. REMOVE FRONT PILLAR GARNISH LH
17. REMOVE FRONT PILLAR GARNISH RH
18. REMOVE INNER REAR VIEW MIRROR ASSEMBLY
a. w/ EC Mirror:
Remove the inner mirror.

b. w/o EC Mirror:
Remove the inner mirror.

19. REMOVE ROOF CONSOLE BOX ASSEMBLY
a. for Short Type:
Remove the roof console box.

b. for Long Type:
Remove the roof console box.

20. REMOVE VISOR BRACKET COVER LH
21. REMOVE VISOR BRACKET COVER RH
22. REMOVE VISOR ASSEMBLY LH
a. for Regular cab:
Remove the visor.

b. for Double cab:
Remove the visor.

23. REMOVE VISOR ASSEMBLY RH

HINT: Use the same procedures described for the LH side.

24. REMOVE VISOR HOLDER
25. REMOVE ASSIST GRIP SUB-ASSEMBLY
26. REMOVE ASSIST GRIP PLUG
27. REMOVE ROOF HEADLINING ASSEMBLY
a. Partially remove the roof headlining.

HINT: It is not necessary to completely remove the roof headlining. Slightly lower the front section of the roof headlining so that the windshield glass can be removed in a later step.

28. REMOVE REAR ROOF DRIP SIDE FINISH MOULDING LH
29. REMOVE REAR ROOF DRIP SIDE FINISH MOULDING RH

HINT: Use the same procedures described for the LH side.

30. REMOVE ROOF DRIP SIDE FINISH MOULDING LH
31. REMOVE ROOF DRIP SIDE FINISH MOULDING RH

HINT: Use the same procedures described for the LH side.

32. REMOVE ROOF DRIP SIDE FINISH MOULDING CLIP
33. REMOVE OUTSIDE WINDSHIELD MOULDING

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

NOTICE: Be careful not to damage the vehicle body.

b. Remove the remaining moulding.

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

34. REMOVE UPPER WINDSHIELD OUTSIDE MOULDING

a. w/ Windshield Deicer:
Remove the clip and disconnect the connector.

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

NOTICE:
- When separating the glass from the vehicle, be careful not to damage the vehicle's paint or interior/exterior ornaments.
- To prevent the instrument panel from being scratched when removing the glass, place a plastic sheet between the piano wire and instrument panel.

e. Place matchmarks over the glass and vehicle body on the locations indicated in the illustration.

HINT: Matchmarks do not need to be placed if not reusing the glass.

f. Cut through the adhesive by pulling the piano wire around the glass.

NOTICE: Leave as much adhesive on the vehicle body as possible when cutting through the adhesive.

g. Disengage the stoppers.

h. Using suction cups, remove the glass.

36. CLEAN WINDSHIELD GLASS

a. Using a scraper, remove the damaged stoppers, dams and adhesive sticking to the glass.
b. Clean the outer edges of the glass with non-residue solvent.

NOTICE: Do not touch the glass surface after cleaning it. Even if using new glass, clean it with nonresidue solvent.

37. CLEAN VEHICLE BODY

a. Clean and shape the contact surface of the vehicle body.
1. On the contact surface of the vehicle body, use a knife to cut away excess adhesive as shown in the illustration.

HINT: Leave as much adhesive on the vehicle body as possible.

NOTICE: Be careful not to damage the vehicle body.

b. Clean the contact surface of the vehicle body with cleaner.

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

INSTALLATION

1. INSTALL NO. 2 WINDSHIELD GLASS STOPPER
a. Apply Primer G to the glass where the spacers will be installed.

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

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

2. INSTALL NO. 1 WINDSHIELD GLASS STOPPER
a. Install 2 new stoppers to the vehicle body as shown in the illustration.

3. INSTALL WINDOW GLASS ADHESIVE DAM
a. Apply Primer G to the glass where the glass adhesive dams will be installed.

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

b. Remove the peeling paper from the adhesive part of the dam. While aligning the dam to the ceramic notch and dam reference line, install the dam (adhesive side) to the glass (Primer G area).

4. INSTALL UPPER WINDSHIELD OUTSIDE MOULDING

a. Using a brush or sponge, coat the edge of the glass and the contact surface with Primer G.

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

b. Install the windshield outside moulding, as shown in the illustration.

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

5. INSTALL WINDSHIELD MOULDING OUTSIDE

a. Install the windshield outside moulding, as shown in the illustration.
b. Apply Primer G to the windshield outside moulding area "a" shown in the illustration.

6. INSTALL WINDSHIELD GLASS

a. 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 to the adhesive.
- Throw away any leftover primer.
- Do not apply too much primer.

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

HINT: If the primer is applied to an area that is not specified, apply non-residue solvent to a clean cloth and wipe off the excess primer.

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

c. Apply adhesive to the glass.
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 written in the table below.

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

d. Install the glass to the vehicle body.

1. Using suction cups, position the glass so that the matchmarks are aligned. Press it in gently along the rim.
2. Lightly press the outer surface of the glass to ensure that it is securely fit to the vehicle body.

NOTICE:
- Check that the stoppers are attached to the vehicle body correctly.
- Check that the vehicle body and glass have a small gap between them.

3. Hold the glass in place securely with protective tape or equivalent until the adhesive hardens.

e. w/ Windshield Deicer:
Install the clip and connect the connector.

7. CHECK FOR LEAKS AND REPAIR
a. Conduct a leak test after the adhesive has completely hardened.
b. Seal any leaks with auto glass sealer.

8. INSTALL ROOF DRIP SIDE FINISH MOULDING CLIP
9. INSTALL ROOF DRIP SIDE FINISH MOULDING LH
10. INSTALL ROOF DRIP SIDE FINISH MOULDING RH

HINT: Use the same procedures described for the LH side.

11. INSTALL REAR ROOF DRIP SIDE FINISH MOULDING LH
12. INSTALL REAR ROOF DRIP SIDE FINISH MOULDING RH

HINT: Use the same procedures described for the LH side.

13. INSTALL ROOF HEADLINING ASSEMBLY
a. Return the roof headlining to its original position.

14. INSTALL ASSIST GRIP PLUG
15. INSTALL ASSIST GRIP SUB-ASSEMBLY
16. INSTALL VISOR HOLDER
17. INSTALL VISOR ASSEMBLY LH
a. for Regular Cab:
Install the visor.

b. for Double Cab:
Install the visor.

18. INSTALL VISOR ASSEMBLY RH

HINT: Use the same procedures described for the LH side.

19. INSTALL VISOR BRACKET COVER LH
20. INSTALL VISOR BRACKET COVER RH
21. INSTALL ROOF CONSOLE BOX ASSEMBLY
a. for Short Type:
Install the roof console box.

b. for Long Type:
Install the roof console box.

22. INSTALL INNER REAR VIEW MIRROR ASSEMBLY
a. w/ EC Mirror:
Install the inner rear view mirror.

b. w/o EC Mirror:
Install the inner rear view mirror.

23. INSTALL FRONT PILLAR GARNISH LH
24. INSTALL FRONT PILLAR GARNISH RH
25. INSTALL LUGGAGE COMPARTMENT BOX RH (for Regular Cab)
26. INSTALL LUGGAGE COMPARTMENT BOX LH (for Regular Cab)
27. INSTALL UPPER BACK PANEL GARNISH (for Regular Cab)
28. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP LH
29. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP RH
30. INSTALL COWL TOP VENTILATOR LOUVER
31. INSTALL FRONT FENDER TO COWL SIDE SEAL LH
32. INSTALL FRONT FENDER TO COWL SIDE SEAL RH
33. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH
34. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH
35. INSTALL FRONT SEAT ASSEMBLY (for Double Cab)
a. Install the front seat.

36. INSTALL FRONT SEAT ASSEMBLY (for Center Seat)
a. Install the front seat.

37. INSTALL FRONT SEAT ASSEMBLY (for Manual Seat)
a. Install the front seat.

38. INSTALL FRONT SEAT ASSEMBLY (for Power Seat)
a. Install the front seat.