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Windshield Glass: Installation

  1. INSTALL WINDSHIELD GLASS STOPPER 
    1. Apply Primer G to the glass where the spacers will be installed.
      NOTE:
      • Allow the primer to dry for 3 minutes or more.
      • Throw away any leftover primer.
      • Do not apply too much primer.
    2. Install 2 new stoppers onto the glass as shown in the illustration.
      Fig 1: Identifying Windshield Glass Stopper
      G05315027Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard measurement 

      STANDARD MEASUREMENT

      Area Specified Condition
      a 4.4 mm (0.173 In.)
      b 40.0 mm (1.574 in.)
  2. INSTALL WINDSHIELD GLASS RETAINER 
    1. Apply Primer G to the glass where the retainer will be installed.
      NOTE:
      • Allow the primer to dry for 3 minutes or more.
      • Throw away any leftover primer.
      • Do not apply too much primer.
    2. Install 2 new retainers onto the glass as shown in the illustration.
      Fig 2: Identifying Windshield Glass Retainer
      G05315028Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard measurement 

      STANDARD MEASUREMENT

      Area Specified Condition
      a 30 mm (1.181 in.)
  3. INSTALL NO. 1 WINDSHIELD GLASS STOPPER 
    1. Install 2 new stoppers to the vehicle body as shown in the illustration.
      Fig 3: Installing Stoppers To Vehicle Body
      G05300220Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL WINDSHIELD GLASS ADHESIVE DAM 
    1. Apply Primer G to the glass where the glass adhesive dams will be installed.
      NOTE:
      • Allow the primer to dry for 3 minutes or more.
      • Throw away any leftover primer.
      • Do not apply too much primer.
    2. Remove the peeling paper from the adhesive part of the dam. Install the dam (adhesive side) to the glass (Primer G area), but exclude the area above the notches on the upper part of the glass.
      Fig 4: Identifying Windshield Glass Adhesive Dam
      G05315030Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard measurement 

      STANDARD MEASUREMENT

      Area Specified Condition
      a 9.5 mm (0.374 in.)
  5. INSTALL WINDSHIELD GLASS 
    1. Position the glass.
      1. Using suction cups, place the glass in the correct position.
      2. Check that the entire contact surface of the glass rim is perfectly even.
      3. Place matchmarks on the glass and vehicle body on the locations indicated in the illustration.

        HINT:

        • Placing matchmarks is necessary only when installing 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.
        Fig 5: Matching Matchmarks On Glass And Vehicle Body
        G05315031Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      4. 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 6: Applying Primer M To Exposed Part Of Vehicle Body
        G05300223Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a brush or sponge, apply Primer G to the contact surface of the glass.
      Fig 7: Identifying Primer Apply Contact Surface Of Glass
      G05315033Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard measurement 

      STANDARD MEASUREMENT

      Area Specified Condition
      a 3.0 mm (0.118 in.)
      b 4.0 mm (0.157 in.)
      c 7.0 mm (0.276 in.)
      d 7.5 mm (0.295 in.)
      e 8.0 mm (0.315 in.)

      HINT:

      If the primer is applied to an area that is not specified, apply a non-residue solvent 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.
    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 REFERENCE

        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.
        Fig 8: Identifying Glass Adhesive Application Area
        G05315034Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Standard measurement 

        STANDARD MEASUREMENT

        Area Specified Condition
        a 12.0 mm (0.472 in.)
        b 8.0 mm (0.315 in.)
        c 3.0 mm (0.118 in.)
        d 7.5 mm (0.295 in.)
    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 9: Installing Glass To Vehicle Body
        G05315035Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. 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 the table below. Minimum time
        MINIMUM TIME REFERENCE

        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
  6. INSTALL RAIN SENSOR (w/ RAIN SENSOR)  (See INSTALLATION )
  7. INSTALL INNER REAR VIEW MIRROR ASSEMBLY  (See INSTALLATION )
  8. INSTALL ROOF HEADLINING ASSEMBLY  (See INSTALLATION )
  9. INSTALL ASSIST GRIP ASSEMBLY 
  10. INSTALL VANITY LIGHT ASSEMBLY  (See INSTALLATION )
  11. INSTALL STEERING SPOT LIGHT ASSEMBLY  (See INSTALLATION )
  12. INSTALL MAP LIGHT ASSEMBLY  (See INSTALLATION )
  13. INSTALL INNER REAR MIRROR COVER 
  14. INSTALL FRONT ROOF TOP GARNISH  (See INSTALLATION )
  15. INSTALL VISOR HOLDER 
  16. INSTALL VISOR ASSEMBLY LH  (See INSTALLATION )
  17. INSTALL VISOR ASSEMBLY RH  (See INSTALLATION )
  18. INSTALL VISOR BRACKET COVER  (See INSTALLATION )
  19. INSTALL FRONT PILLAR GARNISH LH  (See INSTALLATION )
  20. INSTALL FRONT PILLAR GARNISH RH  (See INSTALLATION )
  21. INSTALL FRONT DOOR OPENING TRIM COVER LH  (See INSTALLATION )
  22. INSTALL FRONT DOOR OPENING TRIM COVER RH  (See INSTALLATION )
  23. INSTALL FRONT DOOR SCUFF PLATE LH  (See INSTALLATION )
  24. INSTALL FRONT DOOR SCUFF PLATE RH  (See INSTALLATION )
  25. INSTALL ROOF DRIP SIDE FINISH MOULDING CLIP  (See INSTALLATION )
  26. INSTALL ROOF DRIP SIDE FINISH MOULDING CENTER LH  (See INSTALLATION )
  27. INSTALL ROOF DRIP SIDE FINISH MOULDING CENTER RH  (See INSTALLATION )
  28. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY  (See INSTALLATION )
  29. INSTALL FRONT WIPER ARM LH  (See INSTALLATION )
  30. INSTALL FRONT WIPER ARM RH  (See INSTALLATION )
  31. INSTALL FRONT FENDER TO COWL SIDE SEAL LH  (See INSTALLATION )
  32. INSTALL FRONT FENDER TO COWL SIDE SEAL RH  (See INSTALLATION )
  33. INSTALL ENGINE ROOM SIDE COVER LH  (See INSTALLATION )
  34. INSTALL COOL AIR INTAKE DUCT SEAL  (See INSTALLATION )
  35. CHECK FOR LEAKS AND REPAIR 
    1. Conduct a leak test after the adhesive has completely hardened.
    2. Seal any leaks with auto glass sealer.
  36. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
  37. PERFORM INITIALIZATION 
    1. Perform initialization (see INITIALIZATION (2006/02-2006/07) ).
      NOTE: Certain systems needs to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.
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