Windshield Glass (Convertible): Replacement

HINT:

• The installation procedures are the removal procedures in reverse order. However, only installation procedures requiring additional information are included.
• A bolt without a torque specification is shown in the standard bolt chart (see WINDSHIELD /WINDOWGLASS - SERVICE SPECIFICATIONS ).

1. REMOVE  INNER REAR VIEW MIRROR ASSY   ) 
2. REMOVE ROOF HEADLINING ASSY (See  REPLACEMENT  ) 
   1. Remove the front door scuff plate LH and RH.
   2. Remove the cowl side trim LH and RH.
   3. Remove the front door opening trim weatherstrip LH and RH.
   4. Remove the front piliar garnish LH and RH.
   5. Remove the visor LH and RH.
   6. Remove the 2 visor holders.
   7. Remove the map lamp lens.
   8. Remove the map lamp body.
   9. Remove the roof headlining.
3. REMOVE REMOVABLE ROOF WEATHERSTRIP FRONT 
4. REMOVE WINDSHIELD MOULDING OUTER UPPER 
   1. Using a knife, cut off the moulding as shown in the illustration.
      NOTE: Be careful not to damage the vehicle body with the knife.
   2. Remove the remaining moulding.

   HINT:

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

   Fig 1: Cutting Off The Moulding

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. REMOVE WINDSHIELD GLASS 
   1. Apply protective tape to the outer surface of the vehicle body to minimize scratches.
   2. From the interior, insert piano wires between the vehicle body and windshield glass as shown in the illustration.
   3. Tie objects that can serve as handles (for example, wooden blocks) to all wire ends.
      NOTE:

      • When separating the windshield 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 windshield glass, place a plastic sheet between the piano wire and instrument panel.
      Fig 2: Applying Protective Tape To The Outer Surface Of The Vehicle Body To Minimize Scratches

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   4. Place matchmarks over 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.

   5. Cut through the adhesive by pulling the piano wire around the windshield glass.
   6. Disengage the stoppers.
   7. Using a suction cup, remove the windshield glass.
   NOTE: Leave as much adhesive on the vehicle body as possible when removing the windshield glass.
   Fig 3: Placing Matchmarks Over The Windshield Glass And Vehicle Body

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. CLEAN WINDSHIELD GLASS 
   1. Using a scraper, remove the damaged stopper, retainers, dams and adhesive sticking to the windshield glass.
   2. Clean the outer edges of the windshield glass with white gasoline.
   NOTE:

   • Do not touch the windshield glass surface after cleaning it.
   • Even if using new windshield glass, clean the windshield glass with white gasoline.
   Fig 4: Cleaning The Outer Edges Of The Windshield Glass With White Gasoline

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. CLEAN VEHICLE BODY 
   1. 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.

         NOTE: Be careful not to damage the vehicle body.
      2. Clean the contact surface of the vehicle body with cleaner.

   HINT:

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

   Fig 5: Cleaning And Shape The Contact Surface Of The Vehicle Body

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. INSTALL WINDSHIELD GLASS STOPPER NO. 2 
   1. Apply Primer G to the installation part of the stoppers.
      NOTE:

      • Allow the Primer G to dry for 3 minutes or more.
      • Throw away any leftover Primer G.
      • Do not apply too much Primer G.
   2. Install 2 new stoppers onto the windshield glass as shown in the illustration.

   Specification: 

   SPECIFIED AREA AND MEASUREMENT
   
   

   Area	Measurement
   A	40.0 mm (1.575 in.)
   B	7.0 mm (0.276 in.)
   C	12.5 mm (0.492 in.)

   Fig 6: Installing 2 New Stoppers Onto The Windshield Glass

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. INSTALL WINDSHIELD GLASS STOPPER NO. 1 
   1. Install 2 new stoppers to the vehicle body as shown in the illustration.
   Fig 7: Installing 2 New Stoppers To The Vehicle Body

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. INSTALL WINDSHIELD GLASS RETAINER 
    1. Install 2 new retainers onto the windshield glass as shown in the illustration.
    Fig 8: Installing 2 New Retainers Onto The Windshield Glass

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
11. INSTALL WINDSHIELD ADHESIVE DAM 
    1. Apply Primer G to the installation part of the windshield adhesive dams.
       NOTE:

       • Allow the Primer G to dry for 3 minutes or more.
       • Throw away any leftover Primer G.
       • Do not apply too much Primer G.
    2. Apply double-sided tape along the outer edge of the entire windshield glass except for the area marked D and E in the illustration.
    Fig 9: Applying Double-Sided Tape Along The Outer Edge Of The Entire Windshield Glass Except For The Area Marked D And E In

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    Specification: 

    SPECIFIED AREA AND MEASUREMENT
    
    

    Area	Measurement
    a	7.0 mm (0.276 in.)
    b (left)	60.0 mm (2.362 in.)
    b (center)	40.0 mm (1.575 in.)
    b (right)	60.0 mm (2.362 in.)

12. INSTALL WINDSHIELD GLASS 
    1. Position the windshield glass.
       1. Using a suction cup, 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 over the windshield glass and vehicle body on the locations indicated in the illustration.
          Fig 10: Placing Matchmarks Over The Windshield Glass And Vehicle Body

          Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

          HINT:

          • Placing matchmarks is only necessary if the windshield glass being installed is new. If it is reused windshield glass, matchmarks should already be present.
          • When reusing the windshield glass, check and correct the matchmarks position.
          NOTE: Check that the stoppers and retainers are attached to the vehicle body correctly.
       4. Using a suction cup, remove the windshield glass.
    2. Using a brush, apply Primer M to the exposed part of the vehicle body.
       NOTE:

       • Allow the Primer M 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.
       Fig 11: Applying Primer M To The Exposed Part Of The Vehicle Body

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a brush or sponge, apply Primer G to the contact surface of the windshield glass.

       HINT:

       If Primer G is applied to an area other than that which is specified, wipe off the primer with white gasoline before it dries.

       NOTE:

       • Allow the Primer G to dry for 3 minutes or more.
       • Throw away any leftover Primer G.
       • Do not apply too much Primer G.
       Fig 12: Applying Primer G To The Contact Surface Of The Windshield Glass

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Apply adhesive to the windshield glass.

       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 time written in the table below.

          Usage timeframe: 

          TEMPERATURE AND USAGE TIMEFRAME SPECIFICATION
          
          

          Temperature	Usage Timeframe
          35°C (95°F)	15 minutes
          20°C (68°F)	1 hour 40 minutes
          5°C (41°F)	8 hours

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

       Specification: 

       SPECIFIED AREA AND MEASUREMENT
       
       

       Area	Measurement
       a	3.0 mm (0.118 in.)
       b	12.0 mm (0.472 in.)
       c	8.0 mm (0.315 in.)
       d	16.0 mm (0.630 in.)

       Fig 13: Applying Adhesive To The Windshield Glass

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the windshield glass to the vehicle body.
       1. Using a suction cup, position the windshield glass so that the matchmarks are aligned. Press it in gently along the rim.
       2. Lightly press the front surface of the windshield glass to ensure that the windshield glass is securely fit to the vehicle body.
          NOTE:

          • Check that the stoppers and retainers are attached to the vehicle body correctly.
          • Check that the vehicle body and windshield glass have a small gap between them.
       3. Hold the windshield glass in place securely with protective tape or equivalent until the adhesive hardens.
    Fig 14: Placing Matchmarks Over The Windshield Glass And Vehicle Body

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
13. INSTALL WINDSHIELD MOULDING OUTER UPPER 
    1. Using a brush or sponge, apply Primer G to the contact surface of the windshield glass.
       NOTE:

       • Allow the Primer G to dry for 3 minutes or more.
       • Throw away any leftover Primer G.
       • Do not apply too much Primer G.
    2. Install new windshield moulding outer upper before the adhesive dries.
    NOTE: Do not drive the vehicle for the amount of time written in the table below.

    Minimum time: 

    TEMPERATURE AND TIME PRIOR TO DRIVING VEHICLE
    
    

    Temperature	Minimum time prior to driving vehicle
    35°C (95°F)	1 hour 30 minutes
    20°C (68°F)	5 hours
    5°C (41°F)	24 hours

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