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Windshield Glass: Installation

HINT:

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

    Standard measurement 

    STANDARD MEASUREMENT REFERENCE

    Area Measurement
    a 9 mm (0.35 in.)
    b 25 mm (0.98 in.)
    Fig 1: Installing Stoppers Onto Glass
    G04065711Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL WINDSHIELD GLASS ADHESIVE DAM 
    1. Install new dams with adhesive tape as shown in the illustration.

    Standard measurement 

    STANDARD MEASUREMENT REFERENCE

    Area Measurement
    a 7 mm (0.28 in.)
    b 20 mm (0.79 in.)
    Fig 2: Installing Dams With Adhesive Tape
    G04065712Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE: Do not touch the glass surface after cleaning it.
  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 in the illustration.
        Fig 3: Placing Matchmarks On Glass And Vehicle Body
        G04065713Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        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.
        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.
      Fig 4: Applying Primer M To Exposed Part Of Vehicle Body
      G04065714Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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.
    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.

      Fig 5: Applying Primer G To Contact Surface Of Glass
      G04065715Courtesy 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.
    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 

        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 the illustration.

      Standard measurement 

      STANDARD MEASUREMENT REFERENCE

      Area Measurement
      a 12.0 mm (0.472 in.)
      b 8.0 mm (0.315 in.)
      Fig 6: Applying Adhesive To Glass
      G04065716Courtesy 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.
        Fig 7: Positioning Glass So That Matchmarks Are Aligned
        G04065717Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        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.
      3. Use a scraper to remove any excess or protruding adhesive.
        Fig 8: Removing Excess Protruding Adhesive
        G04065718Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        HINT:

        Make sure that the dam is attached to the body panel, as shown in the illustration.

      4. Hold the glass in place securely with protective tape or equivalent until the adhesive hardens.
        Fig 9: Identifying Attached Dam To Body Panel
        G04065719Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        NOTE: Do not drive the vehicle for the amount of time written in the table below.

        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 MOULDING INSTALLATION AREA 
    1. Apply adhesive to the moulding installation area between the glass and body.

      Sealant: 

      Part No. 08833-00030 or equivalent. 

    Fig 10: Applying Adhesive To Moulding Installation Area Between Glass And Body
    G04065720Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL WINDSHIELD MOULDING OUTER UPPER 
    1. Place a new moulding onto the body and tap it by hand.
    Fig 11: Identifying Windshield Moulding Outer Upper
    G04065721Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL NO. 2 WINDSHIELD MOULDING OUTSIDE 
    1. Using an air riveter with No. 4 nose piece, install 4 new rivets and the moulding.

      HINT:

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

    Fig 12: Identifying Nose Piece Cutting Dimension
    G04065722Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE:
    • Do not prize a riveter. It could damage the riveter and cause loose fitting and mandrel bend.
      Fig 13: Identifying Incorrect Riveter And Mandrel
      G04065723Courtesy 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: Identifying Incorrect Riveter Installing Position
      G04065724Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    • Do not allow gap spacing between the rivet head and the material.
  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 
    Fig 15: Identifying Incorrect Way Of Installing Riveter
    G04065725Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL RAIN SENSOR 
    1. If reusing the sensor:

      Install the new sensor tape.

      1. Remove the used sensor tape from the windshield glass or sensor.
      2. Stick new sensor tape on the lens surface of the sensor indicated by the hatched line.

      Standard measurement 

      STANDARD MEASUREMENT REFERENCE

      Area Measurement
      a 10 mm (0.39 in.)
      Fig 16: Identifying Rain Sensor
      G04065726Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Make sure that no dust or fingerprint is on the sheet surface.
      • Stick the sheet so as not to come out from the placing face.
    2. Install the rain sensor.
      NOTE:
      • If reusing the windshield: Check that no sensor tape remains on the windshield after removing the sensor. In case the tape remains, remove completely.
      • Clean the glass surface with a cloth, etc.
      1. Peel the peeling paper of the sensor tape.
      2. Connect the connector and sensor with the screw.
        Fig 17: Identifying Connector
        G04065727Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. Push the stopper.
        Fig 18: Pushing Stopper
        G04065728Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        HINT:

        Install the sensor harness so that it passes through a hole on the roof headlining.

  14. INSTALL NIGHT VIEW CAMERA ASSEMBLY (w/ Night View System) 
    1. Install the camera by sliding it downward along the front glass, and then tighten the screw.
      Fig 19: Installing Night View Camera Assembly (W/ Night View System)
      G04065729Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Install the camera wire as shown in the illustration.
    2. Connect the connector.
    3. Adjust the camera (see ADJUSTMENT  ).
      Fig 20: Identifying Rain Sensor
      G04065730Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the night view cover with the nut.
      Fig 21: Identifying Night View Cover With Nut
      G04065731Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Do not pinch the night view harness and rain sensor harness in the night view cover. Pass them through a hole on the side of the night view cover.
  15. INSTALL INNER REAR VIEW MIRROR ASSEMBLY 
    1. Install the mirror with the 2 screws.
    2. Connect the connector.
  16. INSTALL ROOF HEADLINING ASSEMBLY 
    Fig 22: Identifying Mirror With Screws
    G04065732Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. INSTALL OVERHEAD CONSOLE BOX 
    1. Connect the connector and console box.
    2. Install the console box with the bolt.
    Fig 23: Identifying Console Box With Bolt
    G04065733Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. INSTALL OVERHEAD CONSOLE BOX (w/ LEXUS Link System) 
    1. Connect the connector.
    2. Install the console box with the bolt.
    3. Attach the switch assembly.
  19. INSTALL VISOR HOLDER 
    1. Install the 2 holders with the 2 screws.
  20. INSTALL CENTER VISOR ASSEMBLY 
    1. Install the 2 visors with the 4 screws.
  21. INSTALL VISOR ASSEMBLY 
    1. Install the 2 visors with the 4 screws, and then connect the 2 connectors.
    2. Install the 2 caps.
  22. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP 
  23. INSTALL FRONT PILLAR GARNISH 
    1. Install the 2 garnishes.
    Fig 24: Identifying Console Box With Bolt
    G04065734Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. INSTALL ASSIST GRIP SUB-ASSEMBLY 
    1. Install the 4 assist grips with the 8 screws, and then install the 8 assist grip plugs.
  25. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
  26. PERFORM INITIALIZATION 
    1. Perform initialization (see INITIALIZATION ).
    NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.
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