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Windshield Glass: Installation

  1. INSTALL NO. 2 WINDSHIELD GLASS STOPPER 
    1. Apply Primer G to the installation part of the stoppers.

      HINT:

      If primer G is applied to an area other than that which 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.
    2. Install 2 new stoppers onto the windshield glass as shown in the illustration.

      Standard measurement 

      Fig 1: Identifying Stoppers Primer Applying Area
      G05541782Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      MEASUREMENT REFERENCE

      Area Measurement
      a 7.7 mm (0.303 in.)
      b 7.7 mm (0.303 in.)
      c 12.5 mm (0.492 in.)
  2. INSTALL NO. 1 WINDSHIELD GLASS STOPPER 
    1. Install 2 new stoppers to the vehicle body as shown in the illustration.
  3. INSTALL WINDSHIELD GLASS ADHESIVE DAM 
    1. Apply Primer G to the glass where the glass adhesive dams will be installed.

      HINT:

      If primer G is applied to an area other than that which is specified, wipe off the primer with white gasoline before it dries.

      Fig 2: Identifying Stoppers To Vehicle Body
      G05541783Courtesy 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.
    2. 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 spacer area A as shown in the illustration.
      Fig 3: Identifying Glass Adhesive Dams Primer Applying Area
      G05541784Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard measurement 

      MEASUREMENT REFERENCE

      Area Measurement
      a 7.0 mm (0.276 in.)
  4. INSTALL WINDSHIELD GLASS 
    1. 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.

        HINT:

        Fig 4: Identifying Matchmarks On Glass And Vehicle Body
        G05541779Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        • 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.
    2. 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.
        Fig 5: Identifying Primer M To Exposed Part Of Vehicle Body
        G05541786Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a brush or sponge, apply Primer G to the contact surface of the glass.
      Fig 6: Identifying Primer Applying Area G To Contact Surface Of Glass
      G05541787Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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.
    4. Apply adhesive to the glass.

      Adhesive: 

      Part No. 08850-00801 or equivalent 

      1. 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 

        TIME AND 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
      2. Load the sealer gun with the cartridge.
      3. Apply adhesive to the glass as shown in the illustration.
        Fig 7: Identifying Adhesive To Glass
        G05541788Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Standard measurement 

        MEASUREMENT REFERENCE

        Area Measurement
        a 12.0 mm (0.472 in.)
        b 8.0 mm (0.315 in.)
        c 3.0 mm (0.118 in.)
    5. Install the glass to the vehicle body.
      1. Using suction cups, position the glass so that the matchmarks are aligned. Press it in gently along the rim.
      2. Lightly press the outer surface of the glass to ensure that it is securely fit to the vehicle body.
        NOTE:
        • Check that the stoppers are attached to the vehicle body correctly.
        • Check that the vehicle body and glass have a small gap between them.
          Fig 8: Identifying Matchmarks On Glass And Vehicle Body
          G05541779Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. Hold the glass in place securely with protective tape or equivalent until the adhesive hardens.
  5. 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 other than that which 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.
    2. Align the moulding's marks with glass notches and install the moulding before the adhesive dries.
      NOTE: Do not drive the vehicle for the amount of time written in the table below.

      Minimum time 

      TEMPERATURE AND TIME SPECIFICATION

      Temperature Minimum time prior to driving vehicle
      35°C (95°F) 1 hour 30 minutes
      20°C (68°F) 5 hours
      5°C(41°F) 24 hours
  6. INSTALL COWL TOP VENTILATOR LOUVER RH 
  7. INSTALL COWL TOP VENTILATOR LOUVER LH  ( INSTALLATION )
  8. INSTALL HOOD TO COWL TOP SEAL  ( INSTALLATION )
  9. INSTALL FRONT WIPER ARM RH  ( INSTALLATION )
  10. INSTALL FRONT WIPER ARM LH  ( INSTALLATION )
  11. INSTALL FRONT WIPER ARM HEAD CAP 
  12. INSTALL ROOF HEADLINING ASSEMBLY  ( INSTALLATION )
  13. INSTALL MAP LIGHT ASSEMBLY  ( INSTALLATION )
  14. INSTALL VISOR HOLDER LH  ( INSTALLATION )
  15. INSTALL VISOR HOLDER RH  ( INSTALLATION )
  16. INSTALL LH VISOR ASSEMBLY  ( INSTALLATION )
  17. INSTALL RH VISOR ASSEMBLY  ( INSTALLATION )
  18. INSTALL ASSIST GRIP SUB-ASSEMBLY  ( INSTALLATION )
  19. INSTALL ASSIST GRIP COVER  ( INSTALLATION )
  20. INSTALL FRONT PILLAR GARNISH LH  ( INSTALLATION )
  21. INSTALL FRONT PILLAR GARNISH RH  ( INSTALLATION )
  22. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP LH 
  23. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP RH 
  24. INSTALL COWL SIDE TRIM SUB-ASSEMBLY LH  ( INSTALLATION )
  25. INSTALL COWL SIDE TRIM SUB-ASSEMBLY RH  ( INSTALLATION )
  26. INSTALL FRONT DOOR SCUFF PLATE LH  ( INSTALLATION )
  27. INSTALL FRONT DOOR SCUFF PLATE RH  ( INSTALLATION )
  28. INSTALL INNER REAR VIEW MIRROR ASSEMBLY  ( INSTALLATION )
  29. CHECK FOR LEAKS AND REPAIR 
    1. Conduct a leak test after the adhesive has completely hardened.
    2. Seal any leaks with auto glass sealer.
  30. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
  31. PERFORM INITIALIZATION 
    1. Perform initialization ( INITIALIZATION ).
      NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.
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