Windshield Glass: Installation

HINT:

A bolt without a torque specification is shown in the standard bolt chart (see SPECIFIED TORQUE FOR STANDARD BOLTS ).

INSTALL NO. 1 INSTRUMENT PANEL CUSHION
1. Remove the cushion.
2. Clean the instrument panel with white gasoline.
3. Install a new cushion to the instrument panel, as shown in the illustration.
  
  Fig 1: Installing Cushion To Instrument Panel
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CLEAN WINDSHIELD GLASS
1. Using a scraper, remove the damaged stoppers, dams and adhesive sticking to the glass.
2. Clean the outer edges of the glass with white gasoline.
  
  Fig 2: Cleaning Outer Edges Of Glass With White Gasoline
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Do not touch the glass surface after cleaning it. Even if using a new glass, clean it with white gasoline.
CLEAN VEHICLE BODY
1. Clean and shape the contact surface of the vehicle body.
  1. On the contact surface of the vehicle body, use a knife to cut away excess adhesive as shown in the illustration.
    HINT:
    
    Leave as much adhesive on the vehicle body as possible.
    
    NOTE: Be careful not to damage the vehicle body.
2. Clean the contact surface of the vehicle body with cleaner.
  
  Fig 3: Removing Excess Adhesive By Using Knife
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  Even if all the adhesive has been removed, clean the vehicle body.

INSTALL NO. 2 WINDSHIELD GLASS STOPPER

Apply Primer G to the installation part of the stoppers.
HINT:

If primer G is applied to an area that is not is specified, wipe off the primer with white gasoline before it dries.
NOTE:
- Allow the primer to dry for 3 minutes or more.
- Throw away any leftover primer.
- Do not apply too much primer.

Install 2 new stoppers onto the windshield glass as shown in the illustration.

Standard measurement

MEASUREMENT SPECIFICATION

Area	Specified Condition
a	40.0 mm (1.575 in.)
b	7.7 mm (0.303 in.)

Fig 4: Installing Stoppers Onto Windshield Glass

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL NO. 1 WINDSHIELD GLASS STOPPER
1. Install 2 new stoppers to the vehicle body as shown in the illustration.

INSTALL WINDSHIELD GLASS ADHESIVE DAM

Apply Primer G to the glass where the glass adhesive dams will be installed.
HINT:

If primer G is applied to an area that is not specified, wipe off the primer with white gasoline before it dries.

Fig 5: Identifying Stopper
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
NOTE:
- Allow the primer to dry for 3 minutes or more.
- Throw away any leftover primer.
- Do not apply too much primer.

Remove the peeling paper from the adhesive part of the dam. Install the dam (adhesive side) to the glass (Primer G area), but exclude the installation parts of the stopper (area c) as shown in the illustration.

Fig 6: Removing Peeling Paper From Adhesive Part Of Dam

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard measurement

MEASUREMENT SPECIFICATION

Area	Specified Condition
a	7.0 mm (0.276 in.)
b	22.0 mm (0.866 in.)
c	10.0 mm (0.394 in.)

INSTALL WINDSHIELD MOULDING OUTSIDE
1. Using a brush or sponge, apply Primer G to the contact surface of the windshield glass.
  HINT:
  
  If primer G is applied to an area that is not specified, wipe off the primer with white gasoline before it dries.
  NOTE:
  - Allow the primer to dry for 3 minutes or more.
  - Throw away any leftover primer.
  - Do not apply too much primer.
2. Install a new windshield molding.

INSTALL WINDSHIELD GLASS

Position the glass.
1. Using suction cups, place the glass in the correct position.
2. Check that the entire contact surface of the glass rim is perfectly even.
3. Place matchmarks on the glass and vehicle body on the locations indicated in the illustration.
  
  Fig 7: Placing Matchmarks On Glass And Vehicle Body
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  - Placing matchmarks is only necessary when installing new glass. If it is the reused glass, matchmarks should already be present.
  - When reusing the glass, check and correct the matchmark positions.
  NOTE: Check that the stoppers are attached to the vehicle body correctly.
4. Using suction cups, remove the glass.
Using a brush, apply Primer M to the exposed part of the vehicle body.
NOTE:
- Allow the primer to dry for 3 minutes or more.
- Do not apply primer to the adhesive.
- Throw away any leftover primer.
- Do not apply too much primer.

Using a brush or sponge, apply Primer G to the contact surface of the glass.

Fig 8: Applying Primer M To Exposed Part Of Vehicle Body

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Fig 9: Applying Primer G To Contact Surface Of Glass

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard measurement

MEASUREMENT SPECIFICATION

Area	Specified Condition
a	7.0 mm (0.276 in.)
b	7.0 mm (0.276 in.)
c	26.5 mm (1.043 in.)

HINT:

If the primer is applied to an area that is not specified, apply white gasoline to a clean cloth and wipe off the excess primer.

NOTE:

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

Apply adhesive to the glass.

Adhesive: Part No. 08850-00801 or equivalent

Fig 10: Applying Adhesive To Glass

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

HINT:

After cutting off the tip, use all adhesive within the time written in the table below.

Usage time frame

TEMPERATURE SPECIFICATION

Temperature	Usage Time Frame
35°C (95°F)	15 minutes
20°C (68°F)	1 hour 40 minutes
5°C (41°F)	8 hours

Load the sealer gun with the cartridge.

Apply adhesive to the glass as shown in the illustration.

Standard measurement

MEASUREMENT SPECIFICATION

Area	Specified Condition
a	8.0 mm (0.315 in.)
b	12.0 mm (0.472 in.)
c	7.0 mm (0.276 in.)
d	26.5 mm (1.043 in.)

Install the glass to the vehicle body.

Using suction cups, position the glass so that the matchmarks are aligned. Press it in gently along the rim.

Fig 11: Placing Matchmarks On Glass And Vehicle Body
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
NOTE:
- Allow the primer to dry for 3 minutes or more.
- Check that the stoppers are attached to the vehicle body correctly.
- Check the clearance between the vehicle body and glass.
Lightly press the outer surface of the glass to ensure that it is securely fit to the vehicle body.

Using a scraper, remove any excess or protruding adhesive.

HINT:

Apply adhesive onto the glass rim.

NOTE: Do not drive the vehicle within the time written in the table below.

Usage time frame

TEMPERATURE SPECIFICATION

Temperature	Usage Time Frame
35°C (95°F)	1 hour 30 minutes
20°C (68°F)	5 hours
5°C (41°F)	24 hours

Fig 12: Removing Protruding Adhesive

INSTALL FRONT FENDER TO COWL SIDE SEAL LH
INSTALL FRONT FENDER TO COWL SIDE SEAL RH
INSTALL COWL TOP VENTILATOR LOUVER RH (See INSTALLATION )
INSTALL COWL TOP VENTILATOR LOUVER LH (See INSTALLATION )
INSTALL HOOD TO COWL TOP SEAL (See INSTALLATION )
INSTALL FRONT WIPER ARM LH (See INSTALLATION )
INSTALL FRONT WIPER ARM RH (See INSTALLATION )
INSTALL FRONT WIPER ARM HEAD CAP
INSTALL ROOF HEADLINING ASSEMBLY (See INSTALLATION )
INSTALL VISOR HOLDER LH (See INSTALLATION )
INSTALL VISOR HOLDER RH (See INSTALLATION )
INSTALL VISOR ASSEMBLY LH (See INSTALLATION )
INSTALL VISOR ASSEMBLY RH (See INSTALLATION )
INSTALL FRONT PILLAR GARNISH LH (See INSTALLATION )
INSTALL FRONT PILLAR GARNISH RH (See INSTALLATION )
INSTALL MAP LIGHT ASSEMBLY (See INSTALLATION )
INSTALL ASSIST GRIP SUB-ASSEMBLY (See INSTALLATION )
INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP LH
INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP RH
INSTALL INNER REAR VIEW MIRROR ASSEMBLY (See INSTALLATION )
CHECK FOR LEAKS AND REPAIR
1. Conduct a leak test after the adhesive has completely hardened.
2. Seal any leaks with auto glass sealer.
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
PERFORM INITIALIZATION
1. Perform initialization (see INITIALIZATION ).
  NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.