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Windshield Glass: Installation

  1. INSTALL WINDSHIELD GLASS NO.1 STOPPER 
    1. Install 2 new stoppers to the vehicle body, as shown in the illustration.
      Fig 1: Installing Stoppers To Vehicle Body
      G05281102Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL WINDSHIELD GLASS NO.2 STOPPER 
    1. Coat the installation part of the stopper with Primer G.
      NOTE:
      • Allow the primer coating to dry for 3 minutes or more.
      • Do not keep any of the opened Primer G for later use.
      • Do not apply too much primer.
    2. Install 2 new windshield glass stoppers onto the glass, as shown in the illustration.

      Standard dimension 

      AREA DIMENSION CHART

      Area Dimension
      A 40.0 mm (1.575 in.)
      B 9.0 mm (0.354 in.)
      C 15.0 mm (0.591 in.)
      Fig 2: Identifying Ceramic Notch
      G05281103Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL WINDSHIELD GLASS RETAINER 
    1. Install a new windshield glass retainer to the glass, as shown in the illustration.
      Fig 3: Identifying Ceramic Notch And Retainer
      G05281104Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL WINDOW GLASS ADHESIVE DAM 
    1. Coat the installation part of the dam with Primer G.
      NOTE:
      • Allow the primer coating to dry for 3 minutes or more.
      • Do not apply too much primer.
    2. Install a new dam, applying double-sided tape all the way around the glass except where the dam is installed, as shown in the illustration.

      Standard dimension 

      AREA DIMENSION CHART

      Area Dimension
      a 9.5 mm (0.374 in.)
      b 50.0 mm (1.969 in.)
      c 8.0 mm (0.315 in.)
  5. INSTALL WINDOW GLASS NO.2 ADHESIVE DAM 
    6. Fig 4: Identifying Window Glass Adhesive Dam
    G05281105Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL WINDSHIELD GLASS 
    1. Clean and shape the contact surface of the vehicle body.
      1. Using a knife, cut away any rough adhesive on the contact surface of the vehicle body to ensure the appropriate surface shape.
        NOTE: Be careful not to damage the vehicle body.

        HINT:

        Leave as much adhesive on the vehicle body as possible.

        Fig 5: Identifying Adhesive Applying Area
        G04967156Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Clean the contact surface of the vehicle body with a piece of shop rag saturated with cleaner.

        HINT:

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

    2. Position the glass.
      1. Using a suction cup, place the glass in the correct position.
      2. Check that the whole contact surface of the glass rim is perfectly even.
      3. Place reference marks between the glass and vehicle body.
        NOTE: Check that the stoppers are attached to the vehicle body correctly.

        HINT:

        When reusing the glass, check and correct the reference mark positions.

        Fig 6: Identifying Matchmarks Over Glass And Vehicle Body
        G05281107Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      4. Remove the glass.
    3. Using a brush, coat the exposed part of the vehicle body on the vehicle side with Primer M.
      NOTE:
      • Allow the primer coating to dry for 3 minutes or more.
      • Do not coat the adhesive with Primer M.
      • Do not keep any of the opened Primer M for later use.
        Fig 7: Identifying Primer Applying Area
        G05281108Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using a brush or sponge, coat the edge of the glass and the contact surface with Primer G.
      NOTE:
      • Allow the primer coating to dry for 3 minutes or more.
      • Do not keep any of the opened Primer G for later use.

      HINT:

      If an area other than that specified is coated by accident, wipe off the primer with a clean shop rag before it dries.

      Fig 8: Identifying Contact Surface With Primer G
      G05281109Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Apply adhesive (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 described in the table below.

        Tackfree time 

        TEMPERATURE REFERENCE CHART

        Temperature Tackfree Time
        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. Coat the glass with adhesive, as shown in the illustration.

        Standard dimension 

        AREA DIMENSION CHART

        Area Dimension
        a 8.0 mm (0.31S in.)
        b 12.0 mm (0.472 in.)
        Fig 9: Applying Adhesive
        G05281108Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Install the glass.
      1. Using a suction cup, position the glass so that the reference marks are aligned, and press it in gently along the rim.
        NOTE:
        • Allow the primer coating to dry for 3 minutes or more.
        • Check that the stoppers are attached to the vehicle body correctly.
        • Check the clearance between the vehicle body and glass.
          Fig 10: Installing Glass
          G05864087Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Lightly press the front surface of the glass to ensure a close fit.
      3. Using a scraper, remove any excess or protruding adhesive.
        NOTE: Take care not to drive the vehicle for the time described in the table below.

        Minimum time 

        TEMPERATURE REFERENCE CHART

        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

        HINT:

        Apply adhesive onto the glass rim.

        Fig 11: Identifying Excess Or Protruding Adhesive
        G05281112Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL WINDSHIELD MOLDING OUTSIDE 
    1. Using a brush or sponge, coat the edge of the glass and the contact surface with Primer G.
      NOTE:
      • Allow the primer coating to dry for 3 minutes or more.
      • Do not coat the adhesive with Primer G.
      • Do not keep any of the opened Primer G for later use.
    2. Install the windshield molding.
  8. CHECK FOR LEAKS AND REPAIR 
    1. Conduct a leak test after the adhesive has completely hardened.
    2. Seal any leaks with auto glass sealer.
  9. INSTALL RAIN SENSOR (w/ Rain Sensor)  (See INSTALLATION )
  10. INSTALL ROOF HEADLINING ASSEMBLY  (See INSTALLATION )
  11. INSTALL ASSIST GRIP SUB-ASSEMBLY  (See INSTALLATION )
  12. INSTALL VISOR HOLDER 
  13. INSTALL VISOR ASSEMBLY LH  (See INSTALLATION )
  14. INSTALL VISOR ASSEMBLY RH 
  15. INSTALL MAP LIGHT ASSEMBLY  (See INSTALLATION )
  16. INSTALL FRONT PILLAR GARNISH LH  (See INSTALLATION )
  17. INSTALL FRONT PILLAR GARNISH RH 
  18. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP LH 
  19. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP RH 
  20. INSTALL INNER REAR VIEW MIRROR STAY HOLDER COVER  (See INSTALLATION )
  21. INSTALL INNER REAR VIEW MIRROR ASSEMBLY  (See INSTALLATION )
  22. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY 
  23. INSTALL FRONT FENDER TO COWL SIDE SEAL LH 
  24. INSTALL FRONT FENDER TO COWL SIDE SEAL RH 
  25. INSTALL FRONT WIPER ARM LH  (See INSTALLATION )
  26. INSTALL FRONT WIPER ARM RH  (See INSTALLATION )
  27. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
  28. PERFORM INITIALIZATION 
    NOTE: Some systems need initialization when disconnecting the cable from the negative (-) battery terminal (See INITIALIZATION ).
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