2003 Toyota Celica Vehicle Type: Two-Door Hatchback

NAGS® numbers:* FW02160 GTN, FD20866-67 Door F/R- L GTN, FQ20868-69 Quarter R-L GTY (Encap), FB20971 Back Window (Heated), FB20970 Back Window (Ant) (Heated). part number is OEM 6320120200. Installation times: , 3.5 hours; front door, 1.7 hours; quarter glass, 2.1 hours; back glass, 1.4 hours; sunroof, 2.1 hours. Technicians needed: One. Helpful tools or supplies: Rubber hose covers or molding retention tape for the fenders and ; marker or pen revealed plastic push-in fasteners with a small clip-removal tool, to mark the stops on the inner-door skin of the door for small hook tool or small flat-head screwdriver. There are three 2003 Toyota Celica 2003 Toyota door glass adjustment. fasteners each on the Watch for: Wipers can sometimes be very hard to driver and passenger remove. To avoid stressing the post, use a wiper puller to sides. See the photos help take the wiper off the post. Make sure the cowling at right. sits under the hood hinges and is fastened to the body • Remove the four with the clips. If the cowling is not in place, this could No. 2 Phillips screws cause damage to the hood, cowling or glass. For the on the top part of the encapsulation of the quarter glass on the upper corner cowling. closest to the door trim, make sure to slip the encapsula- • Using needle-nose tion into the door trim before setting the glass. pliers, remove the two center push-in clips *With permission from the National Auto Glass Specifications on the rubber weather- 2003 Edition Fall Catalog and 2003 Fall Benchmark Calculator. stripping. From the Contact NAGS at 800/551-4012 or visit www.nags.com. underside of the cowl- ing, pinch and push the clips through the holes. • Release the two Windshield clips at the ends of the cowling on the underside of the cowling • Always wear eye and hand protection when working nearest the bottom of the windshield. Use a door-panel with glass. remover. • Make sure that you have the right glass and moldings, and • Cover the hood and areas closest to the bottom of that the urethane you are about to use is current. The molding the windshield by using retention tape or a piece of hose. part numbers are OEM 75531-20370, Precision WFSF2160 and AGC FRM2160. Removal • If you use a cold knife or power tool while working on • Be sure the cutting blades are sufficiently sharp before use. this vehicle, it is recommended that you remove the A • Remove the one-piece molding, starting at the bottom cor- trim panels as the windshield fits very close to the pinchweld. ner of the windshield and pulling in an upward motion 3-to-4 Remove trim panels using an installation stick or a panel inches at a time. remover. There are three fasteners: top, center and about 4 • Before cutting out the windshield, take a few minutes to inches from the bottom of the panel near the dashboard. remove any type of contaminant from the glass and pinchweld. • Cover the front seats, the floorboards, the dash and This step will prevent contaminants from making contact with the with a clean drop cloth or disposable the urethane. 3 plastic covers. • If using a cold knife, try using a ⁄4-inch cold knife blade. Cut • Cover the roof with a hood cover. three sides and use a long knife or a power tool to cut the bottom • Remove the windshield-wiper nut covers using an installa- of the windshield. Be careful not to hit or cut the gravity stops; tion stick or small, flat-tip screwdriver. Remove the windshield- mark their locations with a marking pencil or retention tape. wiper nuts using a 14-millimeter wrench or socket. Push wiper • If trying to save the windshield, try using an Equalizer with arm downward so that the wiper will break loose from the an 8-inch blade. When using an Equalizer, or any power tool, wiper post. use plain water to lubricate the cutting area. Spray the top and • Remove the one-piece cowling by removing the six sides, then make your cuts.

48 AutoGlass™ • 2003–04 Field Guide 2003 Toyota Celica

• After cutting the sides and the top, place a Pumper in the • Apply a triangular bead of urethane to the same path as top center of the windshield to open the cutting area on the bot- the freshly cut urethane on the pinchweld. Before cutting a V- tom portion of the windshield. Never use your head as a pushing notch with a Top Notch tool, cut the tip off of the nozzle with a device as this could result in back and neck injuries. nozzle cutter. Using the cut nozzle, measure to the top of the 1 • Now spray the bottom of the windshield at least 4-to-5 roofline and, adding ⁄16 inch higher than the roofline, make a inches above the urethane on the glass so that the water will mark on the nozzle with a pen or marker. Notch the nozzle up flow down into the urethane while you are making your final to the marked line and this will give you the appropriate trian- cut across the bottom of the windshield. gular bead needed. • Take the windshield out of the opening using a set of vac- • Using vacuum cups, lift the windshield from the windshield uum cups. Lift the glass and place it on a windshield stand or a stand or workstation. Reaching over, place your elbow on the suitable workstation. setting pad on the hood and set the windshield on the stop where you have made your dry-fit mark. Lower the driver side Installation of the windshield onto the urethane and line up with the dry-fit • After cutting the windshield out, remove contaminants mark; it is now in place. (dirt, moisture and other debris) from the pinchweld. This • The windshield is now ready to be decked. Press firmly to would be a good time to clean the dashboard. ensure a good seal. • Be sure to dry fit the new glass to the opening. Make your Disregarding the safe drive-away times that your urethane marks with retention tape or a grease pencil. manufacturer recommends could jeopardize the structural • Place the vacuum cups on the windshield in the appropri- integrity of the and the safety of its passengers. ate location for a one-person set. • Before reinstalling the parts, take a few minutes to • For a driver-side setting of the windshield: While using check for leaks. Use a leak detector to go over the perimeter glass handlers, place the setting elbow pad on the driver side of of the windshield. If there is a leak, apply a little more pressure the hood. Lift the windshield from the windshield stand using to the spot and ensure that the glass makes contact with the the vacuum cups. wet urethane. • Reaching over, place your elbow on the setting pad on the • Reinstall the removed parts in reverse manner. hood and set the windshield onto the stop. Place an alignment mark on your side so that you can easily align the windshield Door Glass when you install it permanently. • Be sure you have the right glass. • With the windshield resting in the opening, go to the pas- • With an installation stick or small screwdriver, remove the senger side and make a dry-fit mark. beauty ring that covers the interior door handle by releasing the • After you have adjusted on the passenger side to the cor- two fasteners that hold the trim at the front and rear of the rect setting, walk back to the driver side, lift the glass and place beauty ring. Remove the No. 2 Phillips screw at the rear of the it on a windshield stand or a suitable workstation. armrest handle under the armrest. • Follow the urethane manufacturer’s recommendations for • Uncover the two 10-millimeter bolts at the front end of installation. the panel by using a flat-tip screwdriver. See photo at right. • Clean the inside of the windshield using what the ure- • Remove the bolts thane manufacturer recommends, following its steps. Do not using a 10-millimeter touch the windshield after cleaning it. socket or No. 1 Phillips • Remember to wear powder-free Nitrile gloves to keep screwdriver if they are from coming in contact with any chemicals. not too tight. With a • Apply the glass prep, following the urethane manufactur- panel-removal tool, er’s recommendations. Do not touch the windshield after release the door trim prepping it. panel, which is held by • Apply the glass primer, following the urethane manufac- eight plastic door-panel turer’s recommendations. Do not touch the windshield after retainers. The retainers priming it. start about 5 inches down from the side and go all around the • Apply the molding to the windshield. Be very careful not panel. The upper part of the panel that looks like it is part of the to touch the freshly primed area. frame has one push-in fastener. • Using a pinchweld scraper, remove as much of the original • Gently pull the door panel and set it in a safe place. urethane as the urethane manufacturer recommends. Before • Peel back the plastic sound-and-weather barrier. removing the old urethane, make sure there are no contami- • Lower the glass to align the mounting hardware to the nants and do not touch the pinchweld after you have prepped opening. Loosen the three 10-millimeter nuts from the carriage. the area. • Remove the front and back stops from the glass. See • Apply the pinchweld primer only to the areas where it is upper photo on next page. needed, and follow the urethane manufacturer’s recommen- • Remove the hardware of the front and rear stops from the dations. Be sure to allow preps and primers to dry as recom- interior door skin using a 10-millimeter socket wrench. Make mended by the urethane manufacturers. marks around the bolt with a pen or marker to ensure that the

AutoGlass™ • 2003–04 Field Guide 49 stops go back on in the the seven panel retainers. The retainers start down from the right spot for alignment. side and go across the panel and up the side to the rear. See lower photo at left. • If trying to save the quarter glass, try using an Equalizer • Disengage the with an 8-inch serrated blade. Adjust the depth of the blade so 1 glass from the carriage that only ⁄4 inch is exposed. When using an Equalizer or any by simultaneously lifting power tool, use plain water to lubricate the cutting area. Spray the rear side of the glass the top, sides and bottom, then make your cuts. and pulling toward you. • Cut around the guidepost so as not to cut the post. Remove the glass. • Be careful not to push too hard on the glass—too much • To replace the door pressure could deform the exterior encapsulation and trim glass, slip the glass back joint, and damage the unit. into the door in the • If the outer part of the encapsulation is glued to the side same manner as it was of the vertical leg, use a small razor knife to cut it free from the removed. Be sure it is in urethane. all three holes before • After cutting the quarter glass out, remove contaminants reinstalling the nuts onto (dirt, moisture and other debris) from the pinchweld. the regulator carriage. • Follow the urethane manufacturer’s recommendation for 2003 Toyota Celica 2003 Toyota • Align the glass with the hardware and tighten the three installation. 10-millimeter nuts. • Clean the inside of the quarter glass, using the material • Reinstall the hardware of the front and rear stops using the manufacturer recommends, and following its steps. Do a 10-millimeter socket wrench. Be sure the marks around the not touch the glass after cleaning it. bolt are in alignment; this will ensure that the stops are in the • Wear powder-free Nitrile gloves to keep from coming in right spot. contact with any chemicals. • Be sure to check the operation of the glass before replac- • Apply the glass prep, following the urethane manufactur- ing the panel to ensure that it operates properly. er’s recommendations. Do not touch the glass after prepping it. • Reinstall the plastic sound-and-weather barrier. • Apply the glass primer, following the urethane • Align the door-panel retainers with the holes, then press or manufacturer’s recommendations. Do not touch the glass push the retainers back into place. after priming it. • Reinstall door-handle beauty ring, two 10-millimeter bolts • Using a pinchweld scraper, remove as much of the and No. 1 Phillips screw. original urethane as the urethane manufacturer recom- mends. Before removing the old urethane, make sure there Quarter Glass are no contaminants and do not touch the pinchweld after • Be sure you have the right glass. you have prepped the area. • Lift the cover on the seat-belt post. • Apply the pinchweld primer only to the areas where it is • Remove 14-millimeter bolt on seat-belt post. See photo needed, and follow the urethane manufacturer’s recommen- below and at left. dations. Be sure to allow preps and primers to dry as recom- mended by the urethane manufacturer. • Apply a triangular bead of urethane to the same path as the freshly cut urethane on the pinchweld. • Lift the quarter glass from the windshield stand or a suitable workstation using vacuum cups. • Slip the encapsulation of the upper corner closest to the door into the door trim. See photo at right. • Remove the coat hanger hook by first using a flat-tip • Align the guide screwdriver to open the small panel cover to the No. 2 Phillips pins to the holes. screw. See photo immediately above and at right. • Set the quarter • Lower the rear seat. glass in the opening. • Loosen the lower by removing the push-on • The quarter glass is clips with a panel remover. Do not skip this step or the upper now ready to be panel could be damaged. The upper panel clips go behind the decked. Press firmly to lower panel. ensure a good seal. • Loosen the fastener on the rear quarter panel that leads • Before reinstalling the parts, take a few minutes to check for to the back of the hatchback area, and the push-on clip on leaks. Use a leak detector to go over the perimeter of the glass. If the upper quarter panel. you find a leak, apply a little more pressure to the spot and make • Remove the upper panel using a panel remover to release sure that the glass makes contact with the wet urethane.

50 AutoGlass™ • 2003–04 Field Guide 2003 Toyota Celica

• Reinstall the removed parts in reverse order. • After the urethane has cured, release the car to the • After the urethane has cured, release the car to the customer. customer.

Back Glass Sunroof • Be sure you have the right glass. The molding part num- • Be sure you have the right glass; the Sunroof is OEM bers are OEM 75531-20380, OEM 64813-20140 and OEM 6320120200. There is trim that is the same color as the car, so Weather Strip 64814- you will need the VIN number or color code to match. 20040. • Open the sunroof slightly so the screws are exposed. • Disconnect the two • Remove the four defroster electrical con- No. 25 Torx screws. nectors, one on each Gently slide out from the side, by sliding the con- rear of the sunroof open- nectors in an outward ing and push up on the motion. See photo to glass to remove it from the right. the rails. There should be • Remove the No. 2 enough clearance not to Phillips head screw come in contact with the wind deflector. See photo above. from the hand pull. • For installation, gently slide in from the rear of the sunroof • With a panel-removal tool, release the back-panel trim opening and place the glass on the rails. Be sure to stay under held by 10 back-panel retainers. the wind deflector with the sunroof. • At this point, follow the same instructions as for the • Tighten the four No. 25 Torx screws; replacement parts, if quarter glass or windshield. needed, are 9014860051. For good measure, check the opera- • When the glass has been installed, connect the two rear tion of the glass by opening and closing several times. defroster wires and reinstall the removed parts in reverse manner. — Gilbert R. Gutierrez

Notes

AutoGlass™ • 2003–04 Field Guide 51