Toyota Avalon (XX50): Windshield Glass

Toyota Avalon (XX50) 2019-2022 Service & Repair Manual / Vehicle Exterior / Window / Glass / Windshield Glass

Components

COMPONENTS

ILLUSTRATION

*1	COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY	*2	FRONT FENDER TO COWL SIDE SEAL LH
*3	FRONT FENDER TO COWL SIDE SEAL RH	*4	FRONT WIPER ARM AND BLADE ASSEMBLY LH
*5	FRONT WIPER ARM AND BLADE ASSEMBLY RH	*6	FRONT WIPER ARM HEAD CAP
	Nm (kgfcm, ft.*lbf): Specified torque	-	-

ILLUSTRATION

*A	for 1-piece Type	*B	for 2-piece Type
*1	FRONT WINDOW INNER CENTER MOULDING	*2	NO. 1 WINDSHIELD GLASS STOPPER
*3	NO. 2 WINDOW GLASS ADHESIVE DAM	*4	NO. 2 WINDSHIELD GLASS STOPPER
*5	WINDOW GLASS ADHESIVE DAM	*6	WINDSHIELD GLASS
*7	WINDSHIELD GLASS SUB-ASSEMBLY	*8	WINDSHIELD OUTSIDE MOULDING
●	Non-reusable part	-	-

Installation

INSTALLATION

CAUTION / NOTICE / HINT

NOTICE:

When replacing the windshield glass of a vehicle equipped with a forward recognition camera, make sure to use a Toyota genuine part. If a non-Toyota genuine part is used, the forward recognition camera may not be able to be installed due to a missing bracket. Also, the dynamic radar cruise control system, lane departure alert system, pre-collision system, front camera system or automatic high beam system may not operate properly due to a difference in the transmissivity or black ceramic border.

PROCEDURE

1. INSTALL NO. 1 WINDSHIELD GLASS STOPPER (for 2-piece Type)

(a) Install 2 new No. 1 windshield glass stoppers to the vehicle body as shown in the illustration.

HINT:

Only 2-piece type windshield glass stoppers are provided as supply parts. Use 2-piece type stoppers as replacements even if 1-piece type stoppers were originally installed.

2. INSTALL NO. 2 WINDSHIELD GLASS STOPPER (for 2-piece Type)

(a) Using a brush or sponge, coat the installation area of 2 new No. 2 windshield glass stoppers with primer G.

NOTICE:

Do not apply too much primer G.
Allow the primer G to dry for 3 minutes or more.
Throw away any leftover primer G.

HINT:

If an area other than specified is coated by accident, wipe off the primer G with a clean piece of cloth before it dries.

(b) Install the 2 new No. 2 windshield glass stoppers to the windshield glass as shown in the illustration.

Standard Dimension:

Area	Dimension
a	15.2 to 16.2 mm (0.598 to 0.638 in.)

HINT:

Only 2-piece type windshield glass stoppers are provided as supply parts. Use 2-piece type stoppers as replacements even if 1-piece type stoppers were originally installed.

*A	Back Side
*a	Ceramic Notch
*b	Windshield Glass Edge Side

3. INSTALL WINDSHIELD OUTSIDE MOULDING

(a) Using a brush or sponge, coat the installation area of a new windshield outside moulding with primer G.

NOTICE:

Do not apply too much primer G.
Allow the primer G to dry for 3 minutes or more.
Throw away any leftover primer G.

HINT:

If an area other than specified is coated by accident, wipe off the primer G with a clean piece of cloth before it dries.

(b) Install the new windshield outside moulding to the windshield glass as shown in the illustration.

Standard Dimension:

Area	Dimension
a	6.65 mm (0.262 in.)

*A	Back Side
*a	Edge Of Curved Surface
*b	Same Length

4. INSTALL WINDOW GLASS ADHESIVE DAM

(a) Using a brush or sponge, coat the installation area of a new window glass adhesive dam with primer G.

NOTICE:

Do not apply too much primer G.
Allow the primer G to dry for 3 minutes or more.
Throw away any leftover primer G.

HINT:

If an area other than specified is coated by accident, wipe off the primer G with a clean piece of cloth before it dries.

(b) Install the new window glass adhesive dam to the windshield glass as shown in the illustration.

*A	Back Side	-	-
*a	Ceramic Notch	*b	Window Glass Adhesive Dam Positioning Center

5. INSTALL NO. 2 WINDOW GLASS ADHESIVE DAM

(a) Using a brush or sponge, coat the installation area of 2 new No. 2 window glass adhesive dams with primer G.

NOTICE:

Do not apply too much primer G.
Allow the primer G to dry for 3 minutes or more.
Throw away any leftover primer G.

HINT:

If an area other than specified is coated by accident, wipe off the primer G with a clean piece of cloth before it dries.

(b) Install 2 new No. 2 window glass adhesive dams to the windshield glass as shown in the illustration.

*A	Back Side	-	-
*a	Ceramic Notch	*b	No. 2 Window Glass Adhesive Dam Positioning Center

6. INSTALL FRONT WINDOW INNER CENTER MOULDING

HINT:

Perform the following procedure only when replacement of the front window inner center moulding is necessary.

(a) Using a brush or sponge, coat the installation area of a new front window inner center moulding with primer G.

Standard Dimension:

Area	Dimension
a	16.0 mm (0.630 in.)

NOTICE:

Do not apply too much primer G.
Allow the primer G to dry for 3 minutes or more.
Throw away any leftover primer G.

HINT:

If an area other than specified is coated by accident, wipe off the primer G with a clean piece of cloth before it dries.

*A	Back Side
	Primer G

(b) Install the new front window inner center moulding to the windshield glass as shown in the illustration.

*A	Back Side	-	-
*a	Matchmark	*b	Ceramic Notch

Standard Dimension:

Area	Dimension
a	0.6 mm (0.0236 in.)

NOTICE:

Do not damage the front window inner center moulding.

7. INSTALL WINDSHIELD GLASS SUB-ASSEMBLY

(a) Position the windshield glass sub-assembly.

(1) Using suction cups, place the windshield glass sub-assembly in the correct position.

(2) Check that the whole contact surface of the windshield glass sub-assembly rim is perfectly even.

(3) Align the matchmarks on the windshield glass sub-assembly and vehicle body.

NOTICE:

Check that the windshield glass stoppers are engaged to the vehicle body correctly.

(4) Remove the windshield glass sub-assembly.

Matchmark

(b) Using a brush, coat the installation surface on the vehicle body with primer M.

NOTICE:

Do not coat the adhesive with primer M.
Do not apply too much primer M.
Allow the primer M to dry for 3 minutes or more.
Throw away any leftover primer M.

HINT:

If an area other than specified is coated by accident, wipe off the primer M with a clean piece of cloth before it dries.

*A	Back Side	-	-
*a	Adhesive Application Area	*b	Ceramic Notch
	Primer G	-	-

Standard Dimension:

Area	Dimension
a	11.0 mm (0.433 in.) or more
b	19.0 mm (0.748 in.) or more

NOTICE:

Do not apply too much primer G.
Allow the primer G to dry for 3 minutes or more.
Throw away any leftover primer G.

HINT:

Apply primer G to the ceramic notches.
If an area other than specified is coated by accident, wipe off the primer G with a clean piece of cloth before it dries.

(d) Apply adhesive to the windshield glass sub-assembly.

Adhesive:

Toyota Genuine Windshield Glass Adhesive (High modulus type) or equivalent

(1) Cut off the tip of the cartridge nozzle as shown in the illustration.

Standard Dimension:

Area	Dimension
a	12.0 to 15.0 mm (0.472 to 0.591 in.)
b	8.0 to 11.0 mm (0.315 to 0.433 in.)

Nozzle

(2) Load the sealer gun with the cartridge.

(3) Apply adhesive to the windshield glass sub-assembly as shown in the illustration.

*A	Back Side	-	-
*a	Adhesive Positioning Center	*b	Ceramic Notch
	Adhesive	-	-

Standard Dimension:

Area	Dimension
a	9.5 mm (0.374 in.)
b	9.5 mm (0.374 in.)
c	4.0 mm (0.158 in.)
d	8.0 to 11.0 mm (0.315 to 0.433 in.)
e	39.4 mm (1.55 in.)

HINT:

Apply adhesive to the ceramic notches.

(e) Install the windshield glass sub-assembly.

(1) Using suction cups, position the windshield glass sub-assembly so that the matchmarks are aligned, and press it in gently along the rim.

NOTICE:

Check that the windshield glass stoppers are engaged to the vehicle body correctly.
Check the clearance between the vehicle body and windshield glass sub-assembly.

(2) Lightly press the outer surface of the windshield glass sub-assembly to ensure that the windshield glass sub-assembly is securely fit to the vehicle body.

HINT:

Press the glass with a force of 98 N (10 kgf, 22.0 lbf) or more.

(3) Using a scraper, remove any excess or protruding adhesive.

(4) Hold the windshield glass sub-assembly using protective tape until the applied adhesive becomes hard.

HINT:

Follow the instructions supplied by the adhesive manufacturer or in the corresponding instruction manual for the minimum amount of time necessary to wait before driving the vehicle.

Matchmark

(f) When replacing the windshield glass sub-assembly or front window inner center moulding with a new one:

(1) Remove the 2 protective retainers from the front window inner center moulding.

NOTICE:

Do not damage the front window inner center moulding.

HINT:

Make sure to remove the protective retainers.

8. INSPECT FOR LEAK

(a) After the adhesive has hardened, apply water from the outside of the vehicle. Check that no water leaks into the cabin.

(b) If water leaks into the cabin, allow the water to dry and add adhesive.

9. INSTALL ROOF HEADLINING ASSEMBLY

Click here

10. INSTALL AIR CONDITIONING THERMISTOR ASSEMBLY

Click here

11. INSTALL FORWARD RECOGNITION CAMERA (w/ Pre-collision System)

Click here

12. INSTALL INNER REAR VIEW MIRROR ASSEMBLY

Click here

13. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

Click here

14. INSTALL FRONT FENDER TO COWL SIDE SEAL LH

Click here

15. INSTALL FRONT FENDER TO COWL SIDE SEAL RH

HINT:

Use the same procedure as for the LH side.

16. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH

Click here

17. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH

Click here

18. INSTALL FRONT WIPER ARM HEAD CAP

Click here

19. INSTALL LOWER WINDSHIELD MOULDING OUTSIDE LH

Click here

20. INSTALL LOWER WINDSHIELD MOULDING OUTSIDE RH

HINT:

Use the same procedure as for the LH side.

Removal

REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization or registration) that must be performed after parts are removed and installed, or replaced during windshield glass sub-assembly removal/installation are shown below.

Necessary Procedure After Parts Removed/Installed/Replaced (for Gasoline Model)

Replaced Part or Performed Procedure	Necessary Procedure	Effect/Inoperative Function when Necessary Procedure not Performed
*: w/ Garage Door Opener System
Forward recognition camera Windshield glass	Adjust forward recognition camera	Dynamic Radar Cruise Control System Front Camera System Lane Departure Alert System (w/ Steering Control) Pre-collision System Lighting System (EXT)
Inner rear view mirror assembly*	Register codes in the garage door opener system	Garage door opener system
Front passenger seat	Zero point calibration (Occupant classification system)	Occupant classification system Passenger airbag ON/OFF indicator Airbag system (Front passenger side) Seat belt warning system (Front passenger)

Necessary Procedure After Parts Removed/Installed/Replaced (for HV Model)

Replaced Part or Performed Procedure	Necessary Procedure	Effect/Inoperative Function when Necessary Procedure not Performed
*: w/ Garage Door Opener System
Forward recognition camera Windshield glass	Adjust forward recognition camera	Dynamic Radar Cruise Control System Front Camera System Lane Departure Alert System (w/ Steering Control) Pre-collision System Lighting System (EXT)
Inner rear view mirror assembly*	Register codes in the garage door opener system	Garage door opener system
Front passenger seat	Zero point calibration (Occupant classification system)	Occupant classification system Passenger airbag ON/OFF indicator Airbag system (Front passenger side) Seat belt warning system (Front passenger)

NOTICE:

PROCEDURE

1. REMOVE LOWER WINDSHIELD MOULDING OUTSIDE LH

Click here

2. REMOVE LOWER WINDSHIELD MOULDING OUTSIDE RH

HINT:

Use the same procedure as for the LH side.

3. REMOVE FRONT WIPER ARM HEAD CAP

Click here

4. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH

Click here

5. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH

Click here

6. REMOVE FRONT FENDER TO COWL SIDE SEAL LH

Click here

7. REMOVE FRONT FENDER TO COWL SIDE SEAL RH

HINT:

Use the same procedure as for the LH side.

8. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

Click here

9. REMOVE INNER REAR VIEW MIRROR ASSEMBLY

Click here

10. REMOVE FORWARD RECOGNITION CAMERA (w/ Pre-collision System)

Click here

11. REMOVE AIR CONDITIONING THERMISTOR ASSEMBLY

Click here

12. REMOVE ROOF HEADLINING ASSEMBLY

Click here

13. REMOVE WINDSHIELD GLASS SUB-ASSEMBLY

(a) Apply protective tape to the area around the installation position of the windshield glass sub-assembly on the vehicle body to prevent it from being scratched.

Protective Tape

(b) Using a knife, cut off the windshield outside moulding as shown in the illustration.

*1	Windshield Glass
*2	Windshield Outside Moulding
*a	Cut

(c) Place matchmarks on the windshield glass sub-assembly and vehicle body at the locations indicated in the illustration.

HINT:

Matchmarks are not necessary if the windshield glass is not going to be reused.

Matchmark

(d) When using a windshield knife:

(1) Apply soapy water to the area around the adhesive.

(2) Insert a windshield knife into the adhesive between the windshield glass sub-assembly and vehicle body.

*a	Windshield Knife
*b	Aligned with Windshield Glass Sub-assembly
	Pull

(3) While keeping the windshield knife perpendicular to the outer surface of the windshield glass sub-assembly, cut the adhesive by pulling the windshield knife around the windshield glass sub-assembly.

NOTICE:

Do not pry the windshield glass sub-assembly with the windshield knife.
Do not use a windshield knife to cut the adhesive on the lower side of the windshield glass sub-assembly.
When separating the windshield glass sub-assembly, be careful not to damage the paint or interior and exterior ornaments.

HINT:

Insert the windshield knife in an area where the gap between windshield glass sub-assembly and vehicle body is large.

(e) When using piano wire:

(1) Pass a piano wire between the vehicle body and windshield glass sub-assembly from the interior.

*1	Windshield Glass Stopper
*2	Front Window Inner Center Moulding
*a	Piano Wire

(2) Tie both wire ends to wooden blocks or similar objects that can serve as handles.

(3) Cut the adhesive by pulling the piano wire around the windshield glass sub-assembly.

NOTICE:

When separating the windshield glass sub-assembly, be careful not to damage the paint or interior and exterior ornaments.
To prevent the safety pad from being scratched when removing the windshield glass sub-assembly, place a plastic sheet between the piano wire and safety pad.
Be careful not to damage the front window inner center moulding.

(f) Disengage the windshield glass stoppers.

*A	for 1-piece Type	*B	for 2-piece Type
*1	No. 1 Windshield Glass Stopper	*2	No. 2 Windshield Glass Stopper

NOTICE:

The No. 1 windshield glass stoppers and No. 2 windshield glass stoppers are installed to the windshield glass sub-assembly as shown in the illustration. Be careful not to damage the windshield glass sub-assembly when cutting the adhesive.
To prevent the windshield glass sub-assembly from falling when performing this operation, be sure to hold the windshield glass sub-assembly using suction cups.

HINT:

Depending on the vehicle, either 1-piece type or 2-piece type stoppers may be present.

(g) Using suction cups, remove the windshield glass sub-assembly.

NOTICE:

Be careful not to drop the windshield glass sub-assembly.
Leave as much adhesive on the vehicle body as possible when removing the windshield glass sub-assembly.

14. REMOVE WINDOW GLASS ADHESIVE DAM

(a) When reusing the windshield glass:

(1) Using a scraper, remove the window glass adhesive dam.

NOTICE:

Be careful not to damage the windshield glass.
Be sure to replace the window glass adhesive dam with a new one.

Back Side

15. REMOVE NO. 2 WINDOW GLASS ADHESIVE DAM

(a) When reusing the windshield glass:

(1) Using a scraper, remove the 2 No. 2 window glass adhesive dams.

NOTICE:

Be careful not to damage the windshield glass.
Be sure to replace the No. 2 window glass adhesive dams with new ones.

Back Side

16. REMOVE WINDSHIELD OUTSIDE MOULDING

(a) When reusing the windshield glass:

(1) Using a scraper, remove the windshield outside moulding.

NOTICE:

Be careful not to damage the windshield glass.
Be sure to replace the windshield outside moulding with a new one.

Back Side

17. REMOVE NO. 1 WINDSHIELD GLASS STOPPER (for 1-piece Type)

(a) When reusing the windshield glass:

(1) Using a scraper, remove the 2 No. 1 windshield glass stoppers.

NOTICE:

Be careful not to damage the windshield glass.
Be sure to replace the 1-piece type No. 1 windshield glass stoppers with new 2-piece type No. 1 and No. 2 windshield glass stoppers.

Back Side

18. REMOVE NO. 2 WINDSHIELD GLASS STOPPER (for 2-piece Type)

(a) When reusing the windshield glass:

(1) Using a scraper, remove the 2 No. 2 windshield glass stoppers.

NOTICE:

Be careful not to damage the windshield glass.
Be sure to replace the No. 2 windshield glass stoppers with new ones.

Back Side

19. REMOVE NO. 1 WINDSHIELD GLASS STOPPER (for 2-piece Type)

(a) Remove the 2 No. 1 windshield glass stoppers from the vehicle body.

NOTICE:

Be sure to replace the No. 1 windshield glass stoppers with new ones.

20. REMOVE FRONT WINDOW INNER CENTER MOULDING

HINT:

Perform the following procedure only when replacement of the front window inner center moulding is necessary.

(a) Place matchmarks on the windshield glass at the locations indicated in the illustration.

*A	Back Side
*a	Matchmark

(b) Using a scraper, remove the front window inner center moulding.

NOTICE:

Be careful not to damage the windshield glass.
Be sure to replace the front window inner center moulding with a new one.

21. CLEAN WINDSHIELD GLASS

(a) When reusing the windshield glass:

(1) Using a scraper, remove any remaining adhesive dam and adhesive residue from the windshield glass.

NOTICE:

Be careful not to damage the windshield glass.

(2) 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 it with a non-residue solvent.

22. CLEAN VEHICLE BODY

(a) Clean and shape the contact surface of the vehicle body.

(1) Using a knife, cut off any excess adhesive on the contact surface of the vehicle body as shown in the illustration.

*a	Vehicle Body
	Adhesive

Standard Dimension:

Area	Dimension
a	1.0 mm (0.0394 in.) or more

NOTICE:

Be careful not to damage the vehicle body.

HINT:

Leave approximately 1.0 mm (0.0394 in.) of adhesive on the vehicle body.

(2) Clean the contact surface of the vehicle body with a piece of cloth saturated with non-residue solvent.

HINT:

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

Window Defogger Wire

Front Wiper Motor

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