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Body & Frame: Windows: Windshield: Installation

  1. CLEAN AND SHAPE CONTACT SURFACE OF BODY 
    1. Using a knife, cut away any rough areas on the body.

      HINT:

      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.

      HINT:

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

    Fig 1: Identifying Adhesive Locations
    G02632463Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. 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: Scraping Off Adhesive And Cleaning Glass With Cleaner
    G02632464Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. 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.

    HINT:

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

    Fig 3: Installing Stoppers To Glass
    G02632465Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL NEW DAMS 

    Install new dams with a double-stick tape as shown in the illustration.

    Fig 4: Installing Dams
    G02632466Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. 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: Identifying Reference Mark Locations
    G02632467Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. 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
    G02632468Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. COAT CONTACT SURFACE OF BODY WITH PRIMER "M" 

    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.
    Fig 7: Applying Primer M To Contact Surface
    G02632469Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. 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.
    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.
    Fig 8: Applying Primer G To Contact Surface
    G02632470Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.
  9. APPLY ADHESIVE 
    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 the table below.

      ADHESIVE - TACKFREE TIME AND TEMPERATURE 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 sealer gun with the cartridge.
    3. Coat the glass with adhesive as shown in the illustration.
      ADHESIVE SPECIFICATION TABLE

      A 12.5 mm (0.492 in.)
      B 8.0 mm (0.315 in.)
      Fig 9: Coating Glass With Adhesive
      G02632471Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL WINDSHIELD GLASS AND MOULDING 
    1. Install the glass, aligning the reference marks using a suction rubber.

      HINT:

      Check that the stoppers are attached to the body correctly.

    2. Lightly press the glass front surface.
      Fig 10: Aligning Reference Marks Using A Suction Rubber
      G02632472Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Correct insufficient or protruded adhesive agent using a spatula.

      HINT:

      Apply the adhesive agent up to the windshield glass edge.

      Fig 11: Applying Adhesive Agent To Windshield Glass Edge
      G02632473Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install a new windshield moulding to the windshield glass before the adhesive agent hardens.

      HINT:

      Install the moulding, aligning the center of moulding with the center of the body.

    5. Remove any excessive adhesive agent before it hardens.
    6. Hold the glass and moulding in place securely with a protective tape or equivalent until the adhesive hardens.
    Fig 12: Aligning The Center Of Moulding With Center Of The Body
    G02632474Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE: Be sure not to drive the vehicle during the time described in the table below.
    MINIMUM TIME BEFORE DRIVING VEHICLE TABLE

    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
  11. INSPECT FOR LEAK AND REPAIR 
    NOTE: Conduct a leak test after the hardening time has elapsed.
  12. INSTALL INNER REAR VIEW MIRROR 
  13. INSTALL FRONT ROOF HEADLINING TRIM 
  14. INSTALL MAP LIGHT ASSEMBLY 
  15. INSTALL SUN VISORS 
  16. INSTALL FRONT PILLAR GARNISHES 
  17. INSTALL COWL TOP VENTILATOR LOUVER 

    HINT:

    Check that the 6 clips on the back side of the cowl louver are surely fixed to the body.

  18. 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.) 

    4. Torque the nuts.

      Torque: 20 N.m (200 kgf.cm, 15 ft.lbf) 

    5. Install the wiper arm head cap.
      Fig 13: Adjusting Installation Positions A Of Wiper Arms
      G02632475Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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