WINDSHIELD GLASS INSTALLATION


  1. CLEAN WINDSHIELD GLASS


    1. A01BAGQ

      Using a scraper, remove the stoppers, dams and adhesive sticking to the windshield glass.

    2. Clean the outer edges of the windshield glass with non-residue solvent.

      Note


      • Do not touch the windshield glass surface after cleaning it.

      • Even if using new windshield glass, clean the windshield glass with non-residue solvent.

  2. CLEAN VEHICLE BODY


    1. A01BEERE02

      Clean and shape the contact surface of the vehicle body.


      1. On the contact surface of the vehicle body, use a knife to cut away excess adhesive as shown in the illustration.

        Tech Tips

        Leave as much adhesive on the vehicle body as possible.

        Note

        Be careful not to damage the vehicle body.

      2. Clean the contact surface of the vehicle body with cleaner.

        Tech Tips

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

  3. INSTALL WINDSHIELD GLASS STOPPER


    1. Apply Primer G to the installation part of the spacers.

      Note


      • Allow the primer to dry for 3 minutes or more.

      • Throw away any leftover Primer G.

      • Do not apply too much Primer G.

    2. Install 2 new spacers onto the windshield glass, as shown in the illustration.

      A01BC94E01
      Specification
      Area Measurement
      a 20.0 mm (0.787 in.)
      b 9.0 mm (0.354 in.)
      c 10.0 mm (0.393 in.)

  4. INSTALL WINDSHIELD GLASS ADHESIVE DAM


    1. Apply Primer G to the installation part of the windshield glass adhesive dams.

      Note


      • Allow the primer to dry for 3 minutes or more.

      • Throw away any leftover Primer G.

      • Do not apply too much Primer G.

    2. Install new windshield glass adhesive dams all the way around the windshield glass except where the spacers are installed, as shown in the illustration.

      A01BDTKE02
      Specification
      Area Measurement
      a 7.0 mm (0.276 in.)
      b 23.2 mm (0.913 in.)

  5. INSTALL WINDSHIELD GLASS


    1. A01BCUXE01

      Position the windshield glass.


      1. Using a suction cup, place the windshield glass in the correct position.

      2. Check that the whole contact surface of the windshield glass rim is perfectly even.

      3. Place matchmarks over the windshield glass and vehicle body on the locations indicated in the illustration.

        Tech Tips


        • Placing matchmarks is only necessary if the windshield glass being installed is new. If it is reused windshield glass, matchmarks should already be present.

        • When reusing the windshield glass, check and correct the matchmark positions.

        Note

        Check that the spacers are attached to the vehicle body correctly.

      4. Using a suction cup, remove the windshield glass.

    2. A01BCEPE01

      Using a brush, apply Primer M to the exposed part of the vehicle body.

      Note


      • Allow the Primer M to dry for 3 minutes or more.

      • Do not apply Primer M to the adhesive.

      • Throw away any leftover Primer M.

      • Do not apply too much Primer M.

    3. Using a brush or sponge, apply Primer G to the contact surface of the windshield glass.

      A01BC0BE01

      Tech Tips

      If Primer G is applied to an area other than that which is specified, wipe off the primer with non-residue solvent before it dries.

      Note


      • Allow the Primer G to dry for 3 minutes or more.

      • Throw away any leftover Primer G.

      • Do not apply too much Primer G.

    4. Apply adhesive.

      Adhesive
      Toyota Genuine Windshield Glass Adhesive or equivalent

      1. A01BAOVE01

        Cut off the tip of the cartridge nozzle, as shown in the illustration.

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

        Tech Tips

        After cutting off the tip, use all adhesive within the time described in the table below.

        Usage timeframe
        Temperature Usage Timeframe
        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 windshield glass as shown as shown in the illustration.

        A01BABFE01
        Specification
        Area Measurement
        a 12.0 mm (0.472 in.)
        b 8.0 mm (0.315 in.)
    5. A01BCYIE01

      Install the windshield glass to the vehicle body.


      1. Using a suction cup, position the windshield glass so that the matchmarks are aligned. Press it in gently along the rim.

      2. Lightly press the front surface of the windshield glass to ensure that the windshield glass is securely fit to the vehicle body.

        Note


        • Allow the primer to dry for 3 minutes or more.

        • Check that the spacers are attached to the vehicle body correctly.

        • Check that the vehicle body and windshield glass have a small gap between them.

      3. Hold the windshield glass in place securely with protective tape or equivalent until the adhesive hardens.

  6. INSTALL WINDSHIELD MOULDING OUTER UPPER


    1. A01BF4FE01

      Using a brush or sponge, apply Primer G to the contact surface of the windshield glass.

      Note


      • Allow the primer to dry for 3 minutes or more.

      • Throw away any leftover Primer G.

      • Do not apply too much Primer G.

    2. Install new windshield moulding outer upper, as shown in the illustration.

      Note

      Do not drive the vehicle for the amount of time described in the table below.

      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

  7. CHECK FOR LEAKS AND REPAIR


    1. Conduct a leak test after the adhesive has completely hardened.

  8. INSTALL WINDSHIELD WIPER MOTOR AND LINK


    1. A01BH24

      Engage the grommet as shown in the illustration.

    2. Install the windshield wiper motor and link assembly with the 2 bolts.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

    3. Connect the connector.

  9. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY


    1. A01BEUDE01

      Body type narrow:


      1. Install the cowl top ventilator louver sub-assembly with the 10 claws and 6 clips.

    2. Body type wide:


      1. Install the cowl top ventilator louver sub-assembly with the 11 claws and 7clips.

    3. Connect the washer hose.

  10. INSTALL COWL VENT COVER LH

  11. INSTALL COWL VENT COVER RH

  12. INSTALL FR WIPER ARM LH


    1. A01BEJEE03

      Operate the wiper, and stop the windshield wiper motor assembly at the automatic stop position.

    2. Clean the wiper arm serrations.

    3. Clean the wiper pivot serrations with a wire brush (when reinstalling).

    4. A01BCEOE01

      Install the front wiper arm and blade assembly LH with the nut at the position as shown in the illustration.

      Torque:
      25 N*m  { 225 kgf*cm, 18 ft.*lbf }

      Tech Tips

      Hold the arm hinge by hand to fasten the nut.

  13. INSTALL FR WIPER ARM RH


    1. A01BEJEE03

      Clean the wiper arm serrations.

    2. Clean the wiper pivot serrations with a wire brush (when reinstalling).

    3. A01BHF4E01

      Install the front wiper arm and blade assembly RH with the nut at the position as shown in the illustration.

      Torque:
      25 N*m  { 225 kgf*cm, 18 ft.*lbf }

      Tech Tips

      Hold the arm hinge by hand to fasten the nut.

  14. INSTALL WINDSHIELD WIPER ARM COVER


    1. Install the 2 windshield wiper arm covers.

    2. Operate the front wipers while spraying water or washer fluid on the windshield. Make sure that the wipers function properly and there is no interference with the vehicle body.

  15. INSTALL INNER REAR VIEW MIRROR ASSEMBLY

  16. INSTALL ROOF NO.1 HEADLINING

  17. INSTALL ROOM LAMP ASSEMBLY NO.1

  18. INSTALL RH VISOR ASSEMBLY

  19. INSTALL LH VISOR ASSEMBLY

  20. INSTALL VISOR HOLDER

  21. INSTALL ASSIST GRIP ASSEMBLY REAR

  22. INSTALL FRONT PILLAR GARNISH LH

  23. INSTALL FRONT PILLAR GARNISH RH

  24. INSTALL ASSIST GRIP

  25. INSTALL FRONT ASSIST GRIP PLUG