Windshield Glass: Installation

HINT:

• Use the same procedures for the LH side and RH side.
• A bolt without a torque specification is shown in the standard bolt table (see SPECIFIED TORQUE FOR STANDARD BOLTS ).

1. INSTALL WINDSHIELD GLASS STOPPER 
   1. Install 2 new stoppers onto the glass as shown in Fig 1.

      Standard measurement 

      WINDSHIELD GLASS STOPPER
      
      

      Area	Measurement
      a	9 mm (0.35 in.)
      b	25 mm (0.98 in.)

      Fig 1: Installing Windshield Glass Stopper

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. INSTALL WINDSHIELD GLASS ADHESIVE DAM 
   1. Install new dams with adhesive tape as shown in Fig 2.

      Standard measurement 

      WINDSHIELD GLASS ADHESIVE DAM
      
      

      Area	Measurement
      a	7 mm (0.28 in.)
      b	20 mm (0.79 in.)

      NOTE: Do not touch the glass surface after cleaning it.
      Fig 2: Installing Windshield Glass Adhesive Dam

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. INSTALL WINDSHIELD GLASS 
   1. Position the glass.
      1. Using suction cups, place the glass in the correct position.
      2. Place matchmarks on the glass and vehicle body on the locations indicated.

         HINT:

         • Placing matchmarks is only necessary when installing a new glass. If it is the reused glass, matchmarks should already be present.
         • When reusing the glass, check and correct the matchmark positions.
         Fig 3: Placing Matchmarks On Glass & Vehicle Body

         Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
         NOTE: Check that the stoppers are attached to the vehicle body correctly.
      3. 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 4: Applying Primer M To Exposed Part Of Vehicle Body

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. Using a brush or sponge, apply Primer G to the contact surface of the glass.

      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.
      Fig 5: Applying Primer G To Contact Surface Of Glass

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   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 Fig 6 .

         HINT:

         After cutting off the tip, use all adhesive within the time written in USAGE TIME FRAME  .

         Usage time frame 

         USAGE TIME FRAME
         
         

         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 Fig 6.

         Standard measurement 

         STANDARD MEASUREMENT
         
         

         Area	Measurement
         a	12.0 mm (0.472 in.)
         b	8.0 mm (0.315 in.)

         Fig 6: Applying Adhesive To Glass

         Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   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 7: Installing Glass To Vehicle Body

         Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. Use a scraper to remove any excess or protruding adhesive.
         Fig 8: Removing Any Excess Or Protruding Adhesive Using Scraper

         Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

         HINT:

         Make sure that the dam is attached to the body panel as shown in Fig 9.

         Fig 9: Making Sure Dam Is Attached To Body Panel

         Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      4. Hold the glass in place securely with protective tape or equivalent until the adhesive hardens.
         NOTE: Do not drive the vehicle for the amount of time written in MINIMUM TIME  .

         Minimum time 

         MINIMUM TIME
         
         

         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

4. CHECK FOR LEAKS AND REPAIR 
   1. Conduct a leak test after the adhesive has completely hardened.
   2. Seal any leaks with auto glass sealer.

      Sealant: Part No. 08833-00030 or equivalent. 

5. APPLY ADHESIVE TO MOLDING INSTALLATION AREA 
   1. Apply adhesive to the molding installation area between the glass and the body.

      Sealant: Part No. 08833-00030 or equivalent. 

      Fig 10: Applying Adhesive To Molding Installation Area

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. INSTALL WINDSHIELD MOLDING OUTER UPPER 
   1. Place a new molding onto the body and tap it by hand.
      Fig 11: Placing Molding Onto Body

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. INSTALL NO. 2 WINDSHIELD MOLDING OUTSIDE 
   1. Using an air riveter with No. 4 nose piece, install 4 new rivets and the molding.

      HINT:

      Before using the air riveter with No. 4 nose piece, cut 5 mm (0.20 in.) at the edge of No. 4 nose piece.

      Fig 12: Installing Rivets And Molding

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      CAUTION:

      • Do not prize a riveter. It could damage the riveter and cause loose fitting and mandrel bend.
        Fig 13: Incorrect Rivet Installation (1 Of 3)

        Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • Do not tilt the riveter when fastening the rivet to the material to avoid loose fitting.
      • Do not allow gap spacing between the rivet head and the material.
        Fig 14: Incorrect Rivet Installation (2 Of 3)

        Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • Do not allow gap spacing between the materials.
        Fig 15: Incorrect Rivet Installation (3 Of 3)

        Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. INSTALL COWL TOP VENTILATOR LOUVER LH 
9. INSTALL COWL TOP VENTILATOR LOUVER RH 
10. INSTALL HOOD TO COWL TOP SEAL 
11. INSTALL FRONT WIPER ARM 
12. INSTALL FRONT WIPER ARM HEAD CAP 
13. INSTALL INNER REAR VIEW MIRROR ASSEMBLY 
    1. Install the mirror with the 2 screws.
    2. Connect the connector.
    Fig 16: Installing Inner Rear View Mirror Assembly

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
14. INSTALL ROOF HEADLINING ASSEMBLY 
15. INSTALL OVERHEAD CONSOLE BOX 
    1. Connect the connector.
    2. Install the console box with the bolt.
    Fig 17: Installing Overhead Console Box

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
16. INSTALL VISOR HOLDER 
    1. Install the 2 holders with the 2 screws.
17. INSTALL CENTER VISOR ASSEMBLY 
    1. Install the visors with the 4 screws.
18. INSTALL VISOR ASSEMBLY 
    1. Install the 2 visors with the 4 screws, and then connect the 2 connectors.
    2. Install the 2 caps.
19. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP 
20. INSTALL FRONT PILLAR GARNISH 
    1. Install the 2 garnishes.
21. INSTALL ASSIST GRIP SUB-ASSEMBLY 
    1. Install the 4 assist grips with the 8 screws, and then install the 8 assist grip plugs.
22. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
23. PERFORM INITIALIZATION 
    1. Perform initialization (see INITIALIZATION ).
       NOTE: Certain systems needs to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.