2009 Toyota Corolla

Windshield and back glass removal and replacement instructions
By Bob Beranek
June 23, 2009
AUTO

Sponsored by Dow Automotive

 

© 2009 National Glass Association. All rights reserved. Visit GlassMagazine.com for glass removal and replacement instructions for more than 400 vehicles. To sign up to receive the For Technicians Only e-bulletin, email FTO@glass.org

Vehicle type: Four-door sedan

NAGS® numbers*: Windshield part numbers FW2899, solar, acoustic interlayer, made in Canada, and FW2959, acoustic interlayer, made in the United States and Japan; back glass FB23697 solar, heated, antenna

Watch for: The windshield is close to the wall of the pinchweld, especially in the bottom corners. Take care during cutout to prevent damage to the paint.

*With permission from National Auto Glass Specifications. Call NAGS at 800/551-4012 or visit http://glass.mitchell.com/.

A. Windshield
Preparation

1. Cover the front seats, floorboards, dash and steering wheel with a clean drop cloth or disposable plastic covers. Note: Always wear eye and hand protection when working with glass. Make sure you have the right glass and moldings and that the urethane systems you are about to use are current. Windshield part number is FW2899.

2. Drape the fender with a fender cover and tape up any vulnerable areas on the vehicle to protect against possible damage. Tape up the defroster vents to prevent debris from falling into the openings.

3. Loosen the 20T Torx set screw at the base of the rearview mirror and slide the mirror off the mirror pad.

4. Remove the windshield-wiper nut covers.

5. Remove the windshield-wiper nuts using a 14-millimeter wrench or socket. Move the wiper arm in an up-and-down motion to break it loose from the post, or use a wiper-puller. Caution: Wipers can sometimes be hard to remove. To avoid stressing the post, use a wiper-puller.

6. The top and side moldings are underside-mounted. The glass comes with or without the molding. If you use an aftermarket molding as a replacement, you will need to miter the corners.

7. The cowl panel is different from other cowls: instead of covering a drain cavity, it is the drain cavity.

To remove the cowl, release and remove the two push-in center retainers in the two corners of the panel. Carefully pinch and lift the seven fasteners on the underside midway back from the leading edge. The access panel over the master cylinder does not need to be removed or opened for panel removal.

After removal, put the cowl panel in a safe place. Note: Before beginning windshield removal, verify the new windshield is the correct one and the urethanes and primers are current. Never use outdated products as this could jeopardize the structural integrity of the vehicle and the safety of its passengers.

Removal
8. Make sure cutting blades are sufficiently sharp.

9. Before cutting out the windshield, remove contaminants from the glass and pinchweld to prevent contact with the urethane.

10. Use the cutting tools of your choice to remove the glass from the adhesive bead. If you use a power tool, lubricate the cutting area with water. Spray the top and sides; then make your cuts. Caution: The glass is close to the wall of the pinchweld, especially in the bottom corners. Take care during cutout to prevent damage to the paint.

11. Take the windshield out of the opening using vacuum cups. Make sure the vacuum cups do not overlap a crack in the glass. Lift the glass and place it on a windshield stand or suitable workstation.

Installation
12. After cutting the windshield out, remove contaminants such as dirt, moisture and debris from the pinchweld. Clean the dashboard.

13. Dry fit the new glass to the opening. Mark your glass using a grease pencil or retention molding tape.

14. Place your vacuum cups on the new windshield in the appropriate location.

15. Set the windshield onto the old urethane.

16. With the windshield resting in the opening, make sure it is in the right spot.

17. Adjust both sides to the correct setting, marking the passenger side, then the driver side. Lift the glass and place it on a windshield stand or suitable workstation.

18. Follow the urethane manufacturer’s recommendations for installation.

19. Clean the inside of the windshield using a urethane manufacturer-recommended product. Do not touch the bonding area of the windshield after cleaning, prepping or priming it.

20. Wear powder-free Nitrile gloves to protect against harsh chemicals.

21. Apply the glass prep and primer following the urethane manufacturer’s recommendations.

22. Using the tool of your choice, remove the original urethane bead, leaving 1-2 millimeters of existing urethane on the pinchweld. Make sure there are no contaminants and do not touch the pinchweld after prepping the area.

23. Apply the pinchweld primer only to the areas where needed, and follow the urethane manufacturer’s recommendations. Allow preps and primers to dry as recommended by the urethane manufacturer.

24. Apply a triangular bead of urethane to the same path as the freshly cut urethane on the pinchweld. Before cutting your V-notch, cut the tip off of your nozzle with a nozzle-cutter. With the cut nozzle, measure to the top of the roofline, and at 1/16-inch higher than the roofline, make a mark on the nozzle with a pen or marker. Notch the nozzle up to the marked line; this will give you the appropriate triangular bead.

25. Lift the windshield from the windshield stand or workstation using vacuum cups. Set the windshield on the urethane at the mark you made during your dry fit. Lower the driver’s side of the windshield onto the urethane and line it up with the dry-fit mark; it is now in place.

26. The windshield is now ready to be decked. Press firmly to ensure a good seal.

27. Before re-installing the parts, check for leaks. Use a leak detector to go over the perimeter of the windshield. If you find a leak, apply more pressure or add more urethane to the spot and ensure that the glass makes contact with the wet urethane.

28. Re-install the removed parts in reverse order.

29. Allow the urethane to cure according to the urethane manufacturer’s recommended cure time before returning the vehicle to the customer. Warning: Disregarding the safe drive-away time that your urethane manufacturer recommends could jeopardize the structural integrity of the vehicle and the safety of its passengers.

30. You have completed the removal and replacement of the windshield.

B. Back glass
Removal

1. Make sure you have the right glass. The glass comes bonded with the underside molding already attached. Part number is FB23697.

2. Remove the side interior quarter panels with your hands and fingers. They can be pulled off easily.

3. Disconnect the defroster and antenna connector leads.

4. Cut out the back glass using the tools of your choice. If you use a power tool, lubricate the cutting area with water. Spray the top and sides; then make your cuts. It should be a relatively easy cutout unless your goal is to salvage the part. The underside molding will be difficult to salvage without damage.

Installation
5. After cutting the back glass out, remove contaminants such as dirt, moisture and other debris from the pinchweld.

6. Dry fit the new glass to the opening. Mark your glass using a grease pencil or retention molding tape.

7. Place your vacuum cups on the new back glass in the appropriate location.

8. Set the glass onto the old urethane.

9. With the glass resting in the opening, make sure it is in the right spot.

10. Adjust both sides to the correct setting. Lift the glass and place it on a windshield stand or suitable workstation.

11. Follow the urethane manufacturer’s recommendations for installation.

12. Clean the inside of the glass using a urethane manufacturer-recommended product. Do not touch the bonding area of the back glass after cleaning, prepping or priming it.

13. Wear powder-free Nitrile gloves to protect against harsh chemicals.

14. Apply the glass prep and primer following the urethane manufacturer’s recommendations.

15. Using the tool of your choice, remove as much of the original urethane bead as the urethane manufacturer recommends. Make sure there are no contaminants and do not touch the pinchweld after prepping the area.

16. Apply the pinchweld primer only to the areas where needed, and follow the urethane manufacturer’s recommendations. Allow preps and primers to dry as recommended by the urethane manufacturer.

17. Apply a triangular bead of urethane to the same path as the freshly cut urethane on the pinchweld. Before cutting your V-notch, cut the tip off of your nozzle with a nozzle-cutter. With the cut nozzle, measure to the top of the roofline, and at 1/16-inch higher than the roofline, make a mark on the nozzle with a pen or marker. Notch the nozzle up to the marked line; this will give you the appropriate triangular bead.

18. Lift the back glass from the windshield stand or workstation using vacuum cups. Set the glass on the urethane at the mark you made during your dry fit. Line it up with the dry-fit marks; it is now in place.

19. The back glass is now ready to be decked. Press firmly to ensure a good seal.

20. Before re-installing the parts, check for leaks. Use a leak detector to go over the perimeter of the glass. If you find a leak, apply more pressure or add more urethane to the spot and ensure that the glass makes contact with the wet urethane.

21. Re-install the removed parts in reverse order.

22. Connect the electrical leads for the defroster and antenna.

23. Check the operation of the back glass electrical systems.

24. Allow the urethane to cure according to the urethane manufacturer’s recommended cure time before returning the vehicle to the customer.

25. You have completed the removal and replacement of the back glass.

© 2009 National Glass Association. All rights reserved. Visit GlassMagazine.com for glass removal and replacement instructions for more than 400 vehicles. To sign up to receive the For Technicians Only e-bulletin, email FTO@glass.org

The author is president of Automotive Glass Experts in Sun Prairie, Wis. Write him at bberanek@aol.com.