Tercel 1995-1996

Windshield Glass

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Removal & Installation



  1. Remove the wiper arms and cowl louver.
  2.  
  3. Remove the front pillar garnishes. Carefully pry the trim from the retaining clips, then pull the trim upwards to remove the it.

    Click image to see an enlarged view

    Fig. Remove the front pillar garnishes. Carefully pry the trim from the retaining clips, then pull the trim upwards to remove the it

  4.  
  5. Remove the inner rear view mirror by unfastening the two bolts, then carefully removing it.
    WARNING
    Be very careful not to damage the body when cutting off the molding.

  6.  
  7. Remove the windshield molding:
    1. Using a knife, carefully cut off the molding as shown in the accompanying illustration.

      Click image to see an enlarged view

      Fig. Using a knife, carefully cut off the molding as shown

    2.  

  8.  
  9. Remove the windshield glass, as follows:
    1. Push piano wire through from the interior. Tie both ends of the wire to wooden blocks. Apply adhesive tape to the outer surface to keep the surface from being scratched.
      NOTE
      When cutting, take care not to damage the paint and interior/exterior ornaments. To prevent scratching the dash panel when removing the windshield, place a plastic sheet between the piano wire and dash panel.



      Click image to see an enlarged view

      Fig. Push piano wire through from the interior. Tie both ends of the wire to wooden blocks

    2.  
    3. Cut the adhesive by pulling the piano wire around it. Leave as much of the adhesive on the body as possible when cutting off the glass.

      Click image to see an enlarged view

      Fig. Cut the adhesive by pulling the piano wire around it. Leave as much of the adhesive on the body as possible when cutting off the glass

    4.  
    5. With the help of an assistant, remove the glass.

      Click image to see an enlarged view

      Fig. Exploded view of the windshield and related components

    6.  

  10.  

To install:

  1. Clean the shape the contact surface of the body:
    1. Cut away any rough areas of the urethane layer on the body with a knife. Clean the contact surface with alcohol.
      NOTE
      Leave as much urethane on the body as possible.



      Click image to see an enlarged view

      Fig. When cutting away the rough areas of the urethane layer on the body, leave as much urethane as possible

    2.  
    3. Clean the cutting surface of the urethane gum with a piece of shop rag saturated in suitable cleaner. Even if all the urethane has been removed, clean the body.
    4.  

  2.  
  3. Clean the removed glass before installation:
    1. Using a scraper, clean any remaining gum from the glass. Clean the surface with a suitable cleaner. Do not touch the glass after it has been cleaned!

      Click image to see an enlarged view

      Fig. Scraping and cleaning the glass. Do NOT touch the glass after it has been cleaned!

    2.  

  4.  
  5. With the help of an assistant, carefully place the glass in position:
    1. Check that all contacting parts of the glass rim are perfectly even.
    2.  
    3. Place reference marks between the glass and body, then remove the glass.

      Click image to see an enlarged view

      Fig. Position the glass very carefully, then place reference marks between the glass and body and remove the glass

    4.  

  6.  
  7. Once again, clean the contact surface of the glass with a suitable cleaner. Do not touch the glass after cleaning it.
  8.  
  9. Install the windshield dam with double-stick tape, as shown in the illustration. Do NOT touch the glass face after cleaning it.

    Click image to see an enlarged view

    Fig. Install the windshield dam with double-stick tape as shown

  10.  
  11. Using a brush, coat the contact surface of the body with primer -M- and note the following:
    1. Let the primer coating dry for a minimum of 3 minutes.
    2.  
    3. Do not coat Primer M to the adhesive.
    4.  
    5. Do not keep any of the opened Primer M for later use.
    6.  

  12.  
  13. Using a brush or sponge, coat the edge of the glass and the contact surface Primer -G-. Wipe if off with a clean shop rag before the primer dries and note the following:
    1. Let the primer coating dry for a minimum of 3 minutes.
    2.  
    3. Do not keep any of the opened Primer G for later use.

      Click image to see an enlarged view

      Fig. Special primers are used on the adhesive and window glass

    4.  

  14.  
  15. Mix the adhesive coating:
    NOTE
    Make sure installation of the glass is finished within the usable time. The mixture should be made in 5 minutes or less.

    1. Thoroughly clean the glass plate and putty spatula with solvent.
    2.  
    3. Thoroughly mix 500 g (17.64 oz.) of the main agent and 2.65 oz. (75 g) of the hardening agent on a glass plate or like object with a putty spatula.
    4.  

  16.  
  17. Apply adhesive, as follows:
    1. Cut off the tip of the cartridge nozzle to make a hole 0.020 in. (5mm) in diameter. Fill the cartridge with adhesive.
    2.  
    3. Load the cartridge into the sealer gun.
    4.  

  18.  
  19. Coat the glass with adhesive on all contact surfaces along the ridge. Note the following:
    1. Adhesive height if adhesive remains on the body: 0.138-0.197 in. (3.5-5.0mm)
    2.  
    3. Adhesive height if NO adhesive remains on the body: 0.31-0.39 in. (8-10mm)
      NOTE
      Make sure the dam is attached to the body panel as shown.



      Click image to see an enlarged view

      Fig. When applying the adhesive, make sure you have the correct amount, which will depend on if adhesive remained on the body or not

    4.  

  20.  
  21. Install the windshield, as follows:
    1. With an assistant, position the glass so the reference marks are lined up, then press in gently around the rim of the contact areas to seat the glass.

      Click image to see an enlarged view

      Fig. With the aid of an assistant, position the glass on the vehicle. Strong suction cups makes this job easier

    2.  
    3. Using a spatula, apply adhesive around the glass rim.
    4.  
    5. Use the spatula to remove the any excess or protruding adhesive.
    6.  
    7. Fasten the glass securely until the adhesive sets.
    8.  

  22.  
  23. After the adhesive has hardened, water test the windshield for leaks. Seal any leaks with a suitable adhesive or auto glass sealer.

    Click image to see an enlarged view

    Fig. Seal any leaks with a suitable adhesive or auto glass sealer

  24.  
  25. Install the windshield molding as follows:
    1. Using a knife, cut off any old adhesive around the molding installation area.
    2.  
    3. Apply adhesive at the molding installation area.
    4.  
    5. Position the new molding onto the body, then tap it in by hand.

      Click image to see an enlarged view

      Fig. Apply adhesive at the molding installation area



      Click image to see an enlarged view

      Fig. Position the new molding onto the body, then tap it in by hand

    6.  

  26.  
  27. Install the interior trim and components removed earlier.
  28.  
  29. Install the cowl trim, wiper arms and hood.
  30.  

 
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