Windshield Glass (For Sedan)

WINDSHIELD GLASS (For Sedan)

Windshield Glass (For Sedan):

REMOVAL

CAUTION: Some of these service operations affect the SRS airbag system. Read the precautionary notices concerning the SRS airbag system before servicing.

1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
Wait for at least 90 seconds after disconnecting the cable to prevent the airbag from working.

2. REMOVE FRONT WIPER ARM HEAD CAP
3. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH
4. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH
5. REMOVE COWL SIDE VENTILATOR SUB-ASSEMBLY LH
6. REMOVE COWL SIDE VENTILATOR SUB-ASSEMBLY RH
7. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY
8. REMOVE FRONT DOOR SCUFF PLATE RH
9. REMOVE FRONT DOOR SCUFF PLATE LH
10. REMOVE INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY RH
11. REMOVE INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY LH
12. REMOVE COWL SIDE TRIM BOARD RH
13. REMOVE COWL SIDE TRIM BOARD LH
14. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP RH
15. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP LH
16. REMOVE FRONT PILLAR GARNISH RH
17. REMOVE FRONT PILLAR GARNISH LH
18. REMOVE ASSIST GRIP COVER
19. REMOVE ASSIST GRIP SUB-ASSEMBLY
20. REMOVE VISOR ASSEMBLY RH
21. REMOVE VISOR ASSEMBLY LH
22. REMOVE VISOR HOLDER RH
23. REMOVE VISOR HOLDER LH
24. REMOVE ROOM LIGHT ASSEMBLY
25. REMOVE MAP LIGHT ASSEMBLY
26. REMOVE INNER REAR VIEW MIRROR
27. REMOVE ROOF HEADLINING ASSEMBLY

HINT: It is not necessary to remove the roof headlining completely. Slightly lower the front section of the roof headlining.

28. REMOVE WINDSHIELD OUTSIDE MOULDING
a. Using a knife, cut off the windshield outside moulding, as shown in the illustration.

NOTICE: Do not damage the vehicle body with the knife.

b. Remove the windshield outside moulding.

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

29. 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 the 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, do not damage the vehicle's paintwork 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. Place matchmarks on the windshield glass and vehicle body in the locations indicated in the illustration.

HINT: Matchmarks do not need to be placed unless the windshield glass is going to be reused.

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

f. Disengage the 2 stoppers.
g. 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 stoppers, dam and adhesive from 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.

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: Do not 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 or piece of cloth saturated with cleaner.

HINT: Clean the vehicle body even if all the adhesive has been removed.

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

4. INSTALL WINDSHIELD GLASS STOPPER NO. 2
a. Apply Primer G to the installation parts 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.

5. INSTALL WINDOW GLASS ADHESIVE DAM
a. Apply Primer G to the installation part of a new dam, as shown in the illustration.

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 new dam with double-sided tape 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 entire contact surface of the windshield glass rim is perfectly even.
3. Place matchmarks on the windshield glass and vehicle body.

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

HINT: When reusing a 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 the 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 those specified, wipe off the primer with a clean shop rag or piece of cloth before it dries.

d. Apply adhesive.

Adhesive:
Toyota Genuine Windshield Glass Adhesive or the equivalent.

1. Cut the tip off the cartridge nozzle, as shown in the illustration.

HINT: After cutting off the tip, use all the adhesive within the times indicated in the table below.

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. Gently press it in 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 there is a small gap between the vehicle body and the windshield glass.

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

NOTICE: Open and close the door gently to prevent the window glass from becoming loose due to the air pressure when the door is closed.

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

HINT: Apply adhesive to the windshield glass rim.

NOTICE: Do not drive the vehicle within the time indicated in the table below.

7. INSTALL WINDSHIELD OUTSIDE MOULDING

NOTICE: After the installation of the window glass, install the moulding before the adhesive hardens.

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

NOTICE:
- Allow the primer coating to dry for 3 minutes or more.
- Do not coat the adhesive with Primer G.
- Throw away any leftover Primer G.

b. Install a new moulding onto the windshield glass, as shown in the illustration.

NOTICE: Make sure that the moulding is securely installed.

8. CHECK FOR LEAKAGE AND REPAIR
a. Conduct a leak test by applying water to the adhesive portions after the adhesive has completely hardened.
b. Seal any leaks with auto glass sealer.

9. INSTALL ROOF HEADLINING ASSEMBLY
10. INSTALL INNER REAR VIEW MIRROR
11. INSTALL MAP LIGHT ASSEMBLY
12. INSTALL ROOM LIGHT ASSEMBLY
13. INSTALL VISOR HOLDER RH
14. INSTALL VISOR HOLDER LH
15. INSTALL VISOR ASSEMBLY RH
16. INSTALL VISOR ASSEMBLY LH
17. INSTALL ASSIST GRIP SUB-ASSEMBLY
18. INSTALL ASSIST GRIP COVER
19. INSTALL FRONT PILLAR GARNISH RH
20. INSTALL FRONT PILLAR GARNISH LH
21. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP RH
22. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP LH
23. INSTALL COWL SIDE TRIM BOARD RH
24. INSTALL COWL SIDE TRIM BOARD LH
25. INSTALL INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY RH
26. INSTALL INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY LH
27. INSTALL FRONT DOOR SCUFF PLATE RH
28. INSTALL FRONT DOOR SCUFF PLATE LH
29. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY
30. INSTALL COWL SIDE VENTILATOR SUB-ASSEMBLY LH
31. INSTALL COWL SIDE VENTILATOR SUB-ASSEMBLY RH
32. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH
33. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH
34. INSTALL FRONT WIPER ARM HEAD CAP
35. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)

36. INSPECT SRS WARNING LIGHT