Body & Frame: Windows: Windshield: Installation

Clean And Shape Contact Surface Of Body
1. Using a knife, cut away any rough areas on the body.
  NOTE: Leave the adhesive on the body as much as possible.
2. Clean the cut surface of the adhesive with a shop rag saturated in cleaner.
  NOTE: Even if all the adhesive has been removed, clean the body.
  
  Fig 1: Cutting Rough Area On Body
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Clean Removed Glass
1. Remove the damaged No. 2 stoppers and dams.
2. Using a scraper, remove the adhesive sticking to the glass.
3. Clean the glass with cleaner.
  NOTE:
  - Be careful not to damage the glass.
  - Do not touch the glass face after cleaning it.
  Fig 2: Cleaning Adhesive To Glass With Scraper
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install New No. 1 Stoppers
Attach new stoppers to the glass so that the ceramic notches on the glass will align with the stoppers as shown in the illustration.

NOTE: Make sure that the stoppers are installed facing the correct direction.

Fig 3: Installing Stopper to Glass
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install New Dams

Fig 4: Installing New Dams
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Install new dams with a double-stick tape as shown in the illustration.
Position Glass
1. Place the glass in the correct position.
2. Check that all contacting parts of the glass rim are set perfectly even.
3. Place reference marks on the glass and body.
4. Remove the glass.
  
  Fig 5: Placing Glass in Correct Position
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Clean Contact Surface Of Glass
Using a cleaner, clean the contact surface which is black-colored area around the entire glass rim.

NOTE: Do not touch the glass face after cleaning it.

Fig 6: Cleaning Contact Surface Of Glass
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Coat Contact Surface Of Body With Primer M

Fig 7: Applying Primer M To Exposed Part
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using a brush, apply Primer M to the exposed part of the body on the vehicle side.
NOTE:
- Allow 3 minutes or more to dry the primer coated surface.
- Do not apply Primer M to the adhesive.
- Do not keep any of the once opened Primer M for later use.
Coat Contact Surface Of Glass With Primer G
1. Using a brush or sponge, coat the edge of the glass and the contact surface with Primer G as shown in the illustration.
  
  Fig 8: Applying Primer G To Contact Surface Of Glass
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. When the primer is applied inappropriately to the area other than the specified, wipe it off with a clean shop rag before the primer dries.
NOTE:
- Allow 3 minutes or more to dry the primer coated surface.
- Do not keep any of the once opened Primer G for later use.

Apply Adhesive

Cut off the tip of the cartridge nozzle.

Part No. 08850-00801 or equivalent

NOTE: After cutting off the tip, use all adhesive within the time described in the table on next page.

TEMPERATURE TIME

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

Load the sealer gun with the cartridge.

Coat the glass with adhesive as shown in the illustration.

Fig 9: Applying Adhesive Coat To Glass

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

ADHESIVE SIZE

Adhesive Dimension	Size
A	12.5 mm (0.492 in.)
B	8.0 mm (0.315 in.)

Install Windshield Glass And Moulding

Install the glass, aligning the reference marks using a suction rubber.

Fig 10: Installing Windshield Glass in Correct Position
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE: Check that the stoppers are attached to the body correctly.
Lightly press the glass front surface.
Correct insufficient or protruded adhesive agent using a spatula.

Fig 11: Applying Adhesive Agent Up to Windshield Glass Edge
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE: Apply the adhesive agent up to the windshield glass edge.
Install a new windshield moulding to the windshield glass before the adhesive agent hardens.

Fig 12: Installing Windshield Moulding To Windshield Glass
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE: Install the moulding, aligning the center of moulding with the center of the body.
Remove any excessive adhesive agent before it hardens.
Hold the glass and moulding in place securely with a protective tape or equivalent until the adhesive hardens.

NOTE: Be sure not to drive the vehicle during the time described in the table below.

TEMPERATURE TIME

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

Inspect For Leak And Repair
NOTE: Conduct a leak test after the hardening time has elapsed.
Install Inner Rear View Mirror
Install Front Roof Headlining Trim
Install Map Light Assembly
Install Sun Visors
Install Front Pillar Garnishes
Install Cowl Top Ventilator Louver
NOTE: Check that the 6 clips on the back side of the cowl louver are surely fixed to the body.
Install Wiper Arms
1. Operate the wiper motor once and turn the wiper switch OFF.
2. Install the wiper arms and tighten the nuts by hand.
3. Adjust the installation positions A of the wiper arms as shown in the illustration.
  A: 25 - 40 mm (0.98 - 1.57 in.)
  
  Fig 13: Adjusting Installation Positions A
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Torque the nuts.
  Torque: 20 N.m (200 kgf.cm, 15 ft.lbf)
5. Install the wiper arm head cap.