Windshield Toyota MR2 W30

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REMOVAL

HINT

Tape the screwdriver tip before using it to pry parts.

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1. REMOVE WIPER ARMS Remove the wiper arm head cap, 2 nuts and 2 wiper arms.
2. REMOVE COWL TOP VENTILATOR LOUVER Remove the 5 screws and 6 clips. Using a screwdriver, remove the cowl top ventilator louver.
3. REMOVE REMOVABLE ROOF HOOK Remove the 2 screws and removable roof hook.
4. REMOVE FRONT PILLAR GARNISH Using a screwdriver, remove the front pillar garnish. Employ the same manner described above to the other side.
5. REMOVE SUN VISORS Remove the 4 screws and sun visors.
6. REMOVE MAP LIGHT ASSEMBLY Using a screwdriver, remove the map light cover. Remove the 2 screws and map light assembly, then disconnect the connector.
7. REMOVE FRONT ROOF HEADLINING TRIM Using a screwdriver, remove the front roof headlining.
8. REMOVE INNER REAR VIEW MIRROR ASSEMBLY
9. REMOVE WINDSHIELD OUTSIDE MOULDING Using a knife, cut off the moulding as shown in the illustration. NOTE: Do not damage the body with the knife. Remove the remaining moulding.
10. REMOVE WINDSHIELD GLASS Insert a piano wire between the body and glass, let it pass through. Tie both wire ends to wooden blocks or similar objects. NOTE: Be careful not to damage the wire harness. Cut the adhesive by pulling the piano wire around it. NOTE: When separating the glass, take care not to damage the paint and exterior ornaments. To prevent the safety pad from being scratched when removing the windshield, place a plastic sheet between the piano wire and safety pad. HINT: Apply a protective tape to the outer surface to keep the surface from being scratched. Remove the glass. NOTE: Leave the adhesive on the body as much as possible when cutting off the glass.

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1. CLEAN AND SHAPE CONTACT SURFACE OF BODY Using a knife, cut away any rough areas on the body. HINT: Leave the adhesive on the body as much as possible. Clean the cut surface of the adhesive with a shop rag saturated in cleaner. HINT: Even if all the adhesive has been removed, clean the body.
2. CLEAN REMOVED GLASS Remove the damaged No. 2 stoppers and dams. Using a scraper, remove the adhesive sticking to the glass. Clean the glass with cleaner. NOTE: Be careful not to damage the glass. Do not touch the glass face after cleaning it.
3. INSTALL NEW NO. 1 STOPPERS Attach new stoppers to the glass so that the ceramic notches on the glass will align with the stoppers as shown in the illustration. HINT: Make sure that the stoppers are installed facing the correct direction.
4. INSTALL NEW DAMS Install new dams with a double-stick tape as shown in the illustration.
5. POSITION GLASS Place the glass in the correct position. Check that all contacting parts of the glass rim are set perfectly even. Place reference marks on the glass and body. Remove the glass.
6. CLEAN CONTACT SURFACE OF GLASS Using a cleaner, clean the contact surface which is black-colored area around the entire glass rim. NOTE: Do not touch the glass face after cleaning it.
7. COAT CONTACT SURFACE OF BODY WITH PRIMER "M" Using a brush, apply Primer M to the exposed part of the body on the vehicle side. NOTE: Allow 3 minutes or more to dry the primer coated surface. Do not apply Primer M to the adhesive. Do not keep any of the once opened Primer M for later use.
8. COAT CONTACT SURFACE OF GLASS WITH PRIMER "G" Using a brush or sponge, coat the edge of the glass and the contact surface with Primer G as shown in the illustration. When the primer is applied in appropriately to the area other than the specified, wipe it off with a clean shop rag before the primer dries. NOTE: Allow 3 minutes or more to dry the primer coated surface. Do not keep any of the once opened Primer G for later use.
9. APPLY ADHESIVE Cut off the tip of the cartridge nozzle. Part No. 08850-00801 or equivalent HINT: After cutting off the tip, use all adhesive within the time described in the table on next page. ADHESIVE TEMPERATURE CHART Temperature Tackfree time 35°C (95°F) 15 minutes 20°C (68°F) 100 minutes 5°C (41°F) 8 hours Load the sealer gun with the cartridge. Coat the glass with adhesive as shown in the illustration. GLASS SPECIFICATION CHART A 12.5 mm (0.492 in.) B 8.0 mm (0.315 in.)
10. INSTALL WINDSHIELD GLASS AND MOULDING Install the glass, aligning the reference marks using a suction rubber. HINT: Check that the stoppers are attached to the body correctly. Lightly press the glass front surface. Correct insufficient or protruded adhesive agent using a spatula. HINT: Apply the adhesive agent up to the windshield glass edge. Install a new windshield moulding to the windshield glass before the adhesive agent hardens. HINT: Install the moulding, aligning the center of moulding with the center of the body. Remove any excessive adhesive agent before it hardens. Hold the glass and moulding in place securely with a protective tape or equivalent until the adhesive hardens. NOTE: Be sure not to drive the vehicle during the time described in the table below. TEMPERATURE SPECIFICATION Temperature Minimum time before driving the vehicle 35°C (95°F) 1.5 hours 20°C (68°F) 5 hours 5°C (41°F) 24 hours
11. INSPECT FOR LEAK AND REPAIR NOTE: Conduct a leak test after the hardening time has elapsed.
12. INSTALL INNER REAR VIEW MIRROR
13. INSTALL FRONT ROOF HEADLINING TRIM
14. INSTALL MAP LIGHT ASSEMBLY
15. INSTALL SUN VISORS
16. INSTALL FRONT PILLAR GARNISH
17. INSTALL COWL TOP VENTILATOR LOUVER HINT: Check that the 6 clips on the back side of the cowl louver are surely fixed to the body.
18. INSTALL WIPER ARMS Operate the wiper motor once and turn the wiper switch OFF. Install the wiper arms and tighten the nuts by hand. Adjust the installation positions A of the wiper arms as shown in the illustration. A: 25 - 40 mm (0.98 - 1.57 in.) Torque the nuts. Torque: 20 N.m (200 kgf.cm, 15 ft.lbf) Install the wiper arm head cap.