Windshield Glass: Installation

CLEAN AND SHARE 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 the adhesive has been removed, clean the body.
  
  Fig 1: Locating Adhesive On Body
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CLEAN REMOVE WINDSHIELD 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.
REPLACE NO.1 WINDSHIELD GLASS STOPPERS (w/No. 1 stopper)
1. Remove the damaged stoppers.
2. Cut off the old adhesive around the stopper installation area.
  NOTE: Be careful not to damage the body.
3. Clean the installation area.
4. Attach new stoppers to the body so that the notches on the body will align with the stoppers as shown in the illustration.
  HINT:
  
  Make sure that the stoppers are installed facing the correct direction.
  
  Fig 3: Attaching New Stoppers To Body So That Notches On Body Will Align With Stoppers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO.2 STOPPER
1. 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.
  
  A: with No. 1 stopper: 8.0 mm (0.315 in.)
  
  with out No. 1 stopper: 8.9 mm (0.350 in.)
  
  Fig 4: Attaching New Stoppers To Glass So Ceramic Notches On Glass Will Align With Stoppers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL WINDSHIELD GLASS DAM
1. Install new dams with adhesive tape as shown in the illustration.
  A: 7.0 mm (0.276 in.)
  
  Fig 5: Installing Dams With Adhesive Tape
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
POSITION WINDSHIELD 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.
CLEAN CONTACT SURFACE OF GLASS
1. 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 7: Cleaning Contact Surface Of Glass
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
COAT CONTACT SURFACE OF BODY WITH PRIMER "M"
1. Using a brush, coat Primer M to the exposed part of body on the vehicle side.
  NOTE:
  Fig 8: Coating Primer M To Exposed Part Of Body On Vehicle Side Using Brush
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - Allow 3 minutes or more to dry the primer coated surface.
  - Do not coat Primer M to the adhesive.
  - Do not keep any of the 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.
2. When the primer is coated wrongly 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 opened Primer G for later use.

APPLY WINDSHIELD ADHESIVE DAM

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 TIME SPECIFICATIONS

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

Load the cartridge into the sealer gun.
Coat the glass with adhesive as shown in the illustration.
A: 12.0 mm (0.472 in.)

B: 8.0 mm (0.315 in.)

Fig 10: Coating Glass With Adhesive
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL WINDSHIELD GLASS

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

Check to see that the stoppers are attached to the body correctly.
Lightly press the glass front surface for close contact.

Fig 11: Aligning Reference Marks Using Suction Rubber
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Correct insufficient or protruded adhesive agent using a spatula.
HINT:

Apply the adhesive agent up to the windshield glass edge.

Fig 12: Applying Adhesive Agent Up To Windshield Glass Edge
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install a new windshield outside upper molding to the windshield glass before the adhesive agent hardens.
HINT:

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

Fig 13: Installing Molding
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Remove any excessive adhesive agent before it hardens.

Hold the glass and molding in place securely with a protective tape or equivalent until the adhesive hardens.

NOTE: Take care not to drive the vehicle during the time described in the table below.

TIME SPECIFICATIONS FOR VEHICLE DRIVING

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

INSTALL WINDSHIELD OUTER UPPER MOLDING

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

Check to see that the stoppers are attached to the body correctly.

Fig 14: Aligning Reference Marks Using Suction Rubber
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Lightly press the glass front surface for close contact.
Correct insufficient or protruded adhesive agent using a spatula.
HINT:

Apply the adhesive agent up to the windshield glass edge.

Fig 15: Applying Adhesive Agent Up To Windshield Glass Edge
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install a new windshield outside upper molding to the windshield glass before the adhesive agent hardens.
HINT:

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

Fig 16: Installing Windshield Outside Upper Molding
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Remove any excessive adhesive agent before it hardens.

Hold the glass and molding in place securely with a protective tape or equivalent until the adhesive hardens.

NOTE: Take care not to drive the vehicle during the time described in the table below.

TIME SPECIFICATIONS FOR VEHICLE DRIVING

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

INSTALL WINDSHIELD OUTSIDE MOLDING
INSPECT FOR LEAK AND REPAIR
NOTE: Contact a leak test after the hardening time has elapsed.
INSTALL ROOF SIDE RAIL WEATHERSTRIP
1. Attach the upper edge of the weatherstrip to body flange. Tap on the weatherstrip by hand.
INSTALL COWL TOP VENTILATOR LOUVER SUBASSEMBLY
INSTALL WIPER ARMS
1. Operate the wipers once and turn the wiper switch OFF.
2. Install the wiper arms and tighten the nuts by hand.
3. Adjust the installation positions of the wiper arms to positions shown in the illustration.
  A: Approx. 25.4 mm (1.000 in.)
  
  B: Approx. 40.0 mm (1.575 in.)
  
  HINT:
  
  When installing the wiper arms, make sure that the tips of the blades are not beyond the ceramic edge as indicated "C" part in the illustration.
  
  Fig 18: Adjusting Installation Positions Of Wiper Arms To Positions
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Torque the 2 nuts.
  Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf)
5. Install the 2 cap.
INSTALL INNER REAR VIEW MIRROR ASSEMBLY (w/Electro chromic inner rear view mirror)
1. Install the inner rear view mirror and torx screw.
  Torque: 2.5 N*m (25 kgf*cm, 22 in.*lbf)
2. Connect the connector.
3. Install the mirror cover.
INSTALL INNER REAR VIEW MIRROR ASSEMBLY
1. Install the inner rear view mirror and torx screw.
  Torque: 2.5 N*m (25 kgf*cm, 22 in.*lbf)
  
  Fig 20: Installing Inner Rear View Mirror Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL ROOF CONSOLE BOX ASSEMBLY
INSTALL VISOR HOLDER
INSTALL VISOR ASSEMBLY
INSTALL FRONT PILLAR GARNISH
INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP