WINDSHIELD GLASS INSTALLATION


  1. INSTALL NO. 2 WINDSHIELD GLASS STOPPER


    1. Apply Primer G to the glass where the stoppers 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.

      A01E1JCE01
      Standard
      Area Measurement
      a 7.7 mm (0.303 in.)
      b 40.0 mm (1.575 in.)

  2. INSTALL NO. 1 WINDSHIELD GLASS STOPPER

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    1. Install 2 new stoppers to the vehicle body as shown in the illustration.

  3. INSTALL WINDOW 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 spacer area A as shown in the illustration.

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      Standard
      Area Measurement
      a 7.0 mm (0.276 in.)

  4. INSTALL WINDSHIELD GLASS

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    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.

        Tech Tips


        • Placing matchmarks is only necessary 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.

      4. Using suction cups, remove the glass.

    2. A01E29HE04

      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.

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

      A01DZ8OE01

      Tech Tips

      If the primer is applied to an area that is not specified, apply 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
      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 written in the table below.

        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.

        A01DX3IE01
        Standard
        Area Measurement
        a 12.0 mm (0.472 in.)
        b 8.0 mm (0.315 in.)
        c 3.0 mm (0.118 in.)
        d 18.3 mm (0.720 in.)
    5. A01DX9QE04

      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.

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

  5. INSTALL OUTER UPPER WINDSHIELD MOULDING

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    1. Using a brush or sponge, apply Primer G to the glass where a new moulding 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. Align the moulding's marks with glass notches and install the moulding before the adhesive dries.

      Note

      Do not drive the vehicle for the amount of time written 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

  6. INSTALL ROOF HEADLINING ASSEMBLY


    1. for Single Cab:

      Install the roof headlining assembly Click here.

    2. for Extra Cab:

      Install the roof headlining assembly Click here.

    3. for Double Cab:

      Install the roof headlining assembly Click here.

  7. INSTALL INNER REAR VIEW MIRROR ASSEMBLY

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    1. Install the mirror in the direction of the white arrow.

    2. Install the cover as shown in the illustration.

  8. INSTALL ASSIST GRIP (w/ Assist Grip)

    Tech Tips

    Use the same procedure for all assist grips.


    1. Install the assist grip with the 2 screws.

    2. Install the screw.

  9. INSTALL VISOR HOLDER LH


    1. Attach the 2 claws to install the visor holder.

    2. Install the screw.

  10. INSTALL VISOR HOLDER RH

    Tech Tips

    Use the same procedure described for the LH side.

  11. INSTALL VISOR ASSEMBLY LH


    1. Install the visor with the 2 screws.

    2. Attach the guide.

  12. INSTALL VISOR ASSEMBLY RH

    Tech Tips

    Use the same procedure described for the LH side.

  13. INSTALL NO. 1 ROOM LIGHT ASSEMBLY (for Single Cab)

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    1. Connect the light connector.

    2. Install the room light with the 2 screws.

    3. A01E0U3E01

      Attach the lens with the 4 claws.

  14. INSTALL MAP LIGHT ASSEMBLY (w/ Map Light)


    1. Connect the connector.

    2. Attach the 2 guides and claw.

    3. Install the 2 screws to install the map light assembly.

  15. INSTALL FRONT PILLAR GARNISH LH


    1. w/ Curtain Shield Airbag:


      1. Remove the protective cover.

    2. Attach the 2 guides and 2 clips to install the front pillar garnish.

  16. INSTALL FRONT PILLAR GARNISH RH

    Tech Tips

    Use the same procedure described for the LH side.

  17. INSTALL FRONT ASSIST GRIP SUB-ASSEMBLY (w/ Assist Grip)

    Tech Tips

    Use the same procedure for both front assist grips.


    1. Install the front assist grip with the 2 screws.

  18. INSTALL NO. 1 FRONT ASSIST GRIP PLUG LH (w/ Assist Grip)

    Tech Tips

    Use the same procedure for both front No. 1 assist grip plugs.


    1. Attach the 2 claws to install the front No. 1 assist grip plug.

  19. INSTALL NO. 1 FRONT ASSIST GRIP PLUG RH (w/ Assist Grip)

    Tech Tips

    Use the same procedure described for the LH side.

  20. INSTALL FRONT DOOR OPENING TRIM LH

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    Text in Illustration
    *1 Paint Mark
    *2 Mark Position

    1. Align the paint mark on the front door opening trim with the mark position on the vehicle and install the front door opening trim as shown in the illustration.

  21. INSTALL FRONT DOOR OPENING TRIM RH

    Tech Tips

    Use the same procedure described for the LH side.

  22. INSTALL COWL TOP VENTILATOR LOUVER LH

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    1. Attach the 5 claws and install the louver.

  23. INSTALL COWL TOP VENTILATOR LOUVER RH

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    1. Attach the 4 claws and install the louver.

  24. INSTALL HOOD TO COWL TOP SEAL

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    1. Attach the 9 clips and install the seal.

  25. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH


    1. A01E1WUE07

      Stop the wiper motor at the automatic stop position.

    2. Clean the wiper arm serration with a round file or equivalent.

    3. Clean the wiper pivot serration with a wire brush.

    4. A01DVAAE01

      Install the arm & blade with the nut. Make sure that the arm & blade comes to the position shown in the illustration.

      Torque:
      19.6 N*m  { 200 kgf*cm, 14 ft.*lbf }

      Tech Tips

      Hold down the arm hinge with your hand while tightening the nut.

  26. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH


    1. A01E1WUE07

      Clean the wiper arm serration with a round file or equivalent.

    2. Clean the wiper pivot serration with a wire brush.

    3. A01DY0CE01

      Install the arm & blade with the nut. Make sure that the arm & blade comes to the position shown in the illustration.

      Torque:
      19.6 N*m  { 200 kgf*cm, 14 ft.*lbf }

      Tech Tips

      Hold down the arm hinge with your hand while tightening the nut.

    4. Operate the front wipers while spraying water or washer fluid on the windshield. Ensure that there is no interference between the blades and pillar.

  27. INSTALL FRONT WIPER ARM HEAD CAP


    1. Install the 2 caps.

  28. CHECK FOR LEAKS AND REPAIR


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

    2. Seal any leaks with auto glass sealer.

  29. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

  30. PERFORM INITIALIZATION


    1. Perform initialization Click here.

      Note

      Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.