WINDSHIELD GLASS INSTALLATION


  1. INSTALL NO. 2 WINDSHIELD GLASS STOPPER (for 2-piece Type)


    1. Using a brush or sponge, coat the application area of the No. 2 windshield glass stoppers with Primer G.

      Note


      • Do not apply too much primer.

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

      • Do not keep any of the opened Primer G for later use.

      Tech Tips

      If an area other than specified is coated by accident, wipe off the primer with a clean piece of cloth before it dries.

    2. Install 2 new No. 2 windshield glass stoppers onto the windshield glass, as shown in the illustration.

      A0160XRE02
      Standard Dimension
      Area Dimension
      A 40.0 mm (1.575 in.)
      B 30.0 mm (1.181 in.)
      C 25.0 mm (0.984 in.)
      D 14.2 mm (0.559 in.)

      Tech Tips

      Only 2-piece type No. 1 windshield glass stoppers are supplied. Use the 2-piece type stoppers even if the 1-piece type stoppers were used.

  2. INSTALL NO. 1 WINDSHIELD GLASS STOPPER (for 2-piece Type)


    1. A0162O1

      Install 2 new No. 1 windshield glass stoppers to the vehicle body, as shown in the illustration.

      Tech Tips

      Only 2-piece type No. 1 windshield glass stoppers are supplied. Use the 2-piece type stoppers even if the 1-piece type stoppers were used.

  3. INSTALL WINDSHIELD OUTSIDE MOULDING


    1. Using a brush or sponge, coat the application area of the windshield outside moulding with Primer G.

      Note


      • Do not apply too much primer.

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

      • Do not keep any of the opened Primer G for later use.

      Tech Tips

      If an area other than specified is coated by accident, wipe off the primer with a clean piece of cloth before it dries.

    2. A0162LHE01

      Install the windshield outside moulding, as shown in the illustration.

      Standard Dimension
      Area Dimension
      a 2.0 mm (0.0787 in.)

  4. INSTALL WINDSHIELD GLASS ADHESIVE DAM


    1. Using a brush or sponge, coat the application area of the windshield glass adhesive dam with Primer G.

      Note


      • Do not apply too much primer.

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

      • Do not keep any of the opened Primer G for later use.

      • Install a new adhesive dam along the ceramic notches.

      Tech Tips

      If an area other than specified is coated by accident, wipe off the primer with a clean piece of cloth before it dries.

    2. Install a new adhesive dam onto the windshield glass, as shown in the illustration.

      A015ZGME01
      Standard Dimension
      Area Dimension
      a 9.5 mm (0.374 in.)

      Note

      Install a new adhesive dam along the dam reference line.

  5. INSTALL WINDSHIELD GLASS


    1. A0161G7E01

      Position the glass.


      1. Using suction cups, 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.

        Tech Tips

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

      4. Remove the glass.

    2. A015ZWIE01

      Using a brush, coat the exposed part of the vehicle body with Primer M.

      Note


      • Do not coat the adhesive with Primer M.

      • Do not apply too much primer.

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

      • Do not keep any of the opened Primer M for later use.

      Tech Tips

      If an area other than specified is coated by accident, wipe off the primer with a clean piece of cloth before it dries.

    3. Using a brush or sponge, coat the edge of the glass and the contact surface with Primer G.

      A015ZLNE01
      Standard Dimension
      Area Dimension
      a 10.2 mm (0.402 in.)
      b 4.0 mm (0.158 in.)
      c 7.0 mm (0.276 in.)
      d 10.2 mm (0.402 in.)
      e 3.0 mm (0.118 in.)
      f 4.0 mm (0.158 in.)

      Note


      • Do not apply too much primer.

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

      • Do not keep any of the opened Primer G for later use.

      Tech Tips


      • Apply Primer G onto the ceramic notches.

      • If an area other than specified is coated by accident, wipe off the primer with a clean piece of cloth before it dries.

    4. Apply adhesive to the glass.

      Adhesive
      Toyota Genuine Windshield Glass Adhesive or equivalent

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

        Tech Tips

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

        Usage Time Frame
        Temperature Tack-free Time
        35°C (95°F) 15 minutes
        20°C (68°F) 1 hour and 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.

        A015YGLE01
        Standard Dimension
        Area Dimension
        a 12.0 mm (0.472 in.)
        b 8.0 mm (0.315 in.)
        c 10.2 mm (0.402 in.)
        d 10.2 mm (0.402 in.)
        e 3.0 mm (0.118 in.)
    5. A015YL4

      Install the glass.


      1. Using suction cups, 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.

      2. Lightly press the front surface of the glass to ensure a close fit.

        Tech Tips

        Press the glass with force of 98 N (10 kgf, 22 lbf) or more.

      3. A015ZLKE01

        Using a scraper, remove any excess or protruding adhesive.

        Note

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

        Minimum Time
        Temperature Minimum time prior to driving vehicle
        35°C (95°F) 1 hour and 30 minutes
        20°C (68°F) 5 hours
        5°C (41°F) 24 hours

        Tech Tips

        Apply adhesive onto the glass rim.

    6. A015ZTJ

      Connect the connector.

  6. INSPECT FOR LEAK AND REPAIR


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

    2. Seal any leaks with a sealer gun.

  7. INSTALL ROOF HEADLINING ASSEMBLY (w/o Sliding Roof)


    1. A01624CE02

      Place the roof headlining in the vehicle from the front right door.

    2. A0161E1

      Engage the hook, 10 claws and 2 clips, and install the roof headlining assembly.

    3. A0160N9

      Connect the roof wire connector and engage each clamp.

    4. Connect each connector to the map light assembly.

  8. INSTALL ROOF HEADLINING ASSEMBLY (w/ Sliding Roof)


    1. A015YVHE02

      Place the roof headlining in the vehicle from the front right door.

    2. A0162ZUE02

      Engage the hook, 10 claws, 8 fasteners and 2 clips, and install the roof headlining assembly.

    3. A0160N9

      Connect the roof wire connector and engage each clamp.

    4. Connect each connector to the map light assembly.

  9. INSTALL RAIN SENSOR TAPE


    1. A0160SZE01

      Peel off the releasing sheet (yellow side) and attach the rain sensor tape on the position indicated in the illustration (the sensor part of the rain sensor) while pushing out air bubbles with fingers.

    2. Peel off the releasing sheet (white side).

      Note


      • When reusing the rain sensor, clean up dirt on the sensor part with a piece of cloth, etc.

      • Do not touch the sensor tape surface directly with fingers.

      Area Measurement
      A 45.5 mm (1.791 in.)
      B 24.7 mm (0.972 in.)
      C 10.0 mm (0.393 in.)
      D 9.8 mm (0.385 in.)

  10. INSTALL RAIN SENSOR


    1. Connect the connector.

    2. A015YV3

      Engage the claw as shown in the illustration to set the position.

    3. Gradually attach the rain sensor to the glass surface to prevent air bubbles from forming in between them.

    4. A0160Q6E01

      Push in the stopper.

      Note


      • Do not touch the sensor tape surface and the glass surface directly with fingers.

      • Clean up dirt on the glass with a piece of cloth, etc.

      • After installing the rain sensor, there should be no air bubbles between the windshield glass and the rain sensor tape.

  11. INSTALL VISOR HOLDER


    1. A015ZR0E01

      Set the claws of the visor holder as shown in the illustration

    2. Engage the claws and install the visor holder.

      Tech Tips

      Use the same procedure to install the holder on the other side.

  12. INSTALL VISOR ASSEMBLY LH


    1. A0162W1

      Install the visor assembly LH with the 2 screws.

  13. INSTALL VISOR ASSEMBLY RH

    Tech Tips

    Use the same procedure for the RH side and the LH side.

  14. INSTALL VISOR BRACKET COVER


    1. A016218

      Engage the 4 claws and install the visor bracket cover.

      Tech Tips

      Use the same procedure to install the cover on the other side.

  15. INSTALL ASSIST GRIP SUB-ASSEMBLY


    1. A015YK0

      Put an assist grip sub-assembly together as shown in the illustration.

    2. Install the assist grip sub-assembly.

      Tech Tips

      Use the same procedure for the other 3 assist grips.

  16. INSTALL INNER REAR VIEW MIRROR ASSEMBLY


    1. Using a "TORX" socket wrench (T20), install the inner rear view mirror with the screw.

      Torque:
      1.8 N*m  { 18 kgf*cm, 16 in.*lbf }

    2. Connect the connector.

  17. INSTALL MAP LIGHT ASSEMBLY (w/o Sliding Roof)


    1. Connect the connector.

    2. Engage the 2 guides.

      A015ZAU

    3. Engage the 2 clips and install the map light assembly.

    4. Install the 2 screws.

    5. Engage the 3 claws and close the cover.

  18. INSTALL MAP LIGHT ASSEMBLY (w/ Sliding Roof)


    1. Connect the connector.

    2. Engage the 2 guides.

      A0161SL

    3. Engage the 2 clips and install the map light assembly.

    4. Install the 2 screws.

    5. Engage the 3 claws and close the cover.

  19. INSTALL INNER REAR VIEW MIRROR STAY HOLDER COVER


    1. A0162JI

      Engage the 2 claws and install the inner rear view mirror stay holder cover as shown in the illustration.

  20. INSTALL FRONT PILLAR GARNISH LH


    1. A0162T2E01

      Install a new clip <A> on the front pillar garnish LH.

    2. Engage the claw and 2 clips, and install the front pillar garnish LH.

  21. INSTALL FRONT DOOR OPENING TRIM COVER LH


    1. A016285

      Engage the 4 claws and install the front door opening trim cover LH.

  22. INSTALL FRONT DOOR SCUFF PLATE LH


    1. A015ZPR

      Engage the 4 clips.

    2. A0161H2

      Engage the 7 claws and install the front door scuff plate LH.

  23. INSTALL FRONT PILLAR GARNISH RH

    Tech Tips

    Use the same procedure for the RH side and the LH side.

  24. INSTALL FRONT DOOR OPENING TRIM COVER RH

    Tech Tips

    Use the same procedure for the RH side and the LH side.

  25. INSTALL FRONT DOOR SCUFF PLATE RH

    Tech Tips

    Use the same procedure for the RH side and the LH side.

  26. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY


    1. Engage the 11 claws.

      A015ZI2
    2. A015ZRH

      Install the cowl top ventilator louver sub-assembly with the 2 clips.

  27. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH


    1. Operate the wiper and stop the windshield wiper motor at the automatic stop position.

    2. A0161WUE01

      Clean the wiper arm serrations.

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

    4. A0160ONE01

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

      Torque:
      22 N*m  { 224 kgf*cm, 16 ft.*lbf }

      Tech Tips

      Hold the arm hinge by hand to fasten the nut.

      Area Measurement
      A 15 to 30 mm (0.591 to 1.18 in.)
      B Approx. 40 mm (1.57 in.)

  28. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH


    1. Operate the wiper and stop the windshield wiper motor at the automatic stop position.

    2. A0161WUE01

      Clean the wiper arm serrations.

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

    4. A0162P6E01

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

      Torque:
      22 N*m  { 224 kgf*cm, 16 ft.*lbf }

      Tech Tips

      Hold the arm hinge by hand to fasten the nut.

      Area Measurement
      A 16 to 31 mm (0.630 to 1.22 in.)
      B Approx. 20 mm (0.787 in.)

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

  29. INSTALL FRONT WIPER ARM HEAD CAP


    1. A015YS0

      Install the front wiper arm head cap.

      Tech Tips

      Use the same procedure for the RH side and LH side.

  30. INSTALL NO. 1 WINDSHIELD OUTSIDE MOULDING CLIP


    1. Install the 5 No. 1 windshield outside moulding clips.

      A0161PKE01

  31. INSTALL ROOF DRIP SIDE FINISH MOULDING LH


    1. Engage the 2 clips and install the center roof drip side finish moulding.

      A0163FV

  32. INSTALL ROOF DRIP SIDE FINISH MOULDING RH

    Tech Tips

    Use the same procedure for the RH side and the LH side.

  33. INSTALL FRONT UPPER FENDER PROTECTOR LH


    1. A0162I4

      Engage the claw and the 4 clips and install the front upper fender protector LH.

    2. Engage the clip on the rubber portion of the cowl top ventilator louver sub-assembly with the front upper fender protector LH.

  34. INSTALL FRONT UPPER FENDER PROTECTOR RH

    Tech Tips

    Use the same procedure for the RH side and the LH side.

  35. INSTALL ENGINE ROOM SIDE COVER RH (for LHD)


    1. A0161AL

      Install the engine room side cover RH with the 3 clips.

  36. INSTALL ENGINE ROOM SIDE COVER RH (for RHD)


    1. A015YK3

      Install the engine room side cover RH with the 4 clips.

  37. INSTALL ENGINE ROOM SIDE COVER LH (for LHD)


    1. A016120

      Install the engine room side cover LH with the 5 clips.

  38. INSTALL ENGINE ROOM SIDE COVER LH (for RHD)


    1. A015Z63

      Install the engine room side cover LH with the 4 clips.

  39. INSTALL COOL AIR INTAKE DUCT SEAL


    1. A01638L

      Install the cool air intake duct seal with the 9 clips.