Body & Frame: Windows: Windshield: Installation

1. Using a knife, cut away any rough areas on the body.

   HINT:

   Leave as much of the adhesive on the body as possible.

2. Clean the cutting surface of the adhesive with a piece of shop rag saturated in cleaner.

   HINT:

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

   Fig 1: Cleaning & Shaping Contact Surface Of Body

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the damaged stoppers.
2. Cut off the old adhesive around the stoppers installation area.
   NOTE: Be careful not to damage the body.
3. Clean the installation area.
4. Attach new stoppers to the glass with the ceramic notch on the glass aligned with the stoppers, as shown in Fig 2.
   Fig 2: Attaching New Stoppers To Glass

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the damaged retainers.
2. Cut off the old adhesive around the retainers installation area.
   NOTE: Be careful not to damage the body.
3. Clean the installation area.
4. Attach new retainers to the glass with the ceramic notch on the glass aligned with the retainers, as shown in Fig 3.
   Fig 3: Attaching New Retainers To Glass

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a scraper, remove the adhesive sticking to the glass.
2. Clean the glass with cleaner.
   NOTE:

   • Be careful not to damage the glass.
   • Do not touch the glass after cleaning it.

   Fig 4: Cleaning Removed Glass

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Install new dams with double-stick tape as shown in Fig 5.

A: 6.1 mm (0.240 in.) 

Fig 5: Installing New Dams With Double Stick Tape

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1. Place the glass in the correct position.
2. Check that all contacting parts of the glass rim are perfectly even.
3. Place reference marks between the glass and body.
4. Remove the glass.
   Fig 6: Positioning Glass

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Using a cleaner, clean the contact surface which is black-colored area around the entire glass rim.

Fig 7: Cleaning Contact Surface Of Glass

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Using a brush, coat Primer M to the exposed part of body on the vehicle side.

1. Using a brush or sponge, coat the edge of the glass and the contact surface with Primer G.
2. Before the primer dries, wipe it off with a clean shop rag.
   NOTE:

   • Let the primer coating dry for 3 minutes or more.
   • Do not keep any of the opened Primer M for later use.
     Fig 9: Coating Edge Of Glass & Contact Surface With Primer G

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. 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 TEMPERATURE & TACK FREE TIME TABLE .

   TEMPERATURE & TACK FREE TIME TABLE
   
   

   Temperature	Tackfree time
   35°C (95°F)	15 minutes
   20°C (68°F)	100 minutes
   5°C (41°F)	8 hours

2. Load the cartridge into the sealer gun.
3. Coat the glass with adhesive as shown in Fig 10.
   • A: 12.5 mm (0.492 in.) 
   • B: 8.0 mm (0.315 in.) 
   Fig 10: Coating Glass With Adhesive

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

Confirm that the dam is attached to the body panel as shown in Fig 11.

Fig 11: Confirming Dam Attached To Body Panel

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1. Position the glass so that the reference marks are lined up, and press in gently along the rim.
2. Using a spatula, apply adhesive on the glass rim.
   Fig 12: Positioning Glass & Pressing Gently Along Rim

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Use a scraper to remove any excess or protruding adhesive.
   Fig 13: Removing Excess Or Protruding Adhesive Using Scraper

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Hold the windshield glass in place securely with a protective tape or equivalent until the adhesive hardens.
   NOTE: Take care not to drive the vehicle during the time described in TEMPERATURE & MINIMUM TIME PRIOR TABLE .
   TEMPERATURE & MINIMUM TIME PRIOR TABLE
   
   

   Temperature	Minimum time prior to driving the vehicle
   35°C (95°F)	1.5 hours
   20°C (68°F)	5 hours
   5°C (41°F)	24 hours

1. Conduct a leak test after the hardening time has elapsed.
2. Seal any leak with sealant.

   Part No. 08833-00030 or equivalent. 

Apply adhesive to the molding installation area between the glass and the body.

Part No. 08833-00030 or equivalent. 

Fig 14: Applying Adhesive To Molding Installation Area

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Place a new molding onto the body and tap it by hand.

Fig 15: Installing Windshield Upper Molding

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Using an air riveter with nose piece, strike rivets into the body panel to install the windshield outside molding clips to the body panel as shown in Fig 16.

Fig 16: Striking Rivets Into Body Panel Using Air Riveter With Nose Piece

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Fig 17: Positioning Rivets Perpendicular On Mandrel

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Torque: 22 N.m (220 kgf.cm, 16 ft.lbf) 

1. Install the front portion of roof headlining.
2. w/ Sliding roof:

   Install the opening trim.

1. Install the front pillar garnish and cover.
2. Install the bolt.

   Torque: 9.8 N.m (100 kgf.cm, 7 ft.lbf) 

3. Close the cover.
4. Use the same manner described above to the other side.
   Fig 18: Installing Front Pillar Garnish & Cover With Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the inner rear view mirror.
2. Using a torx socket wrench, install the bolt.
   • Torx wrench: T30 (Part No. 09042-00010 or locally manufactured tool) 
   • Torque: 3.7 N.m (38 kgf.cm, 33 in.lbf) 
   Fig 19: Installing Inner Rear View Mirror

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the cover.

1. Connect the connectors.
2. Install the map lamp assembly with the 4 screws.
3. Install the lens and cover.