GSIC - Global Service Information Center

# WINDSHIELD GLASS > INSTALLATION

## for Preparation Click here

1. INSTALL WINDSHIELD GLASS SPACER

1. Apply Primer G to the glass where the spacers will be installed.

   NOTICE:
   1. Allow the primer to dry for 3 minutes or more.
   2. Throw away any leftover primer.
   3. Do not apply too much primer.

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

   Specification:

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

2. INSTALL NO.1 WINDSHIELD GLASS STOPPER

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.

   NOTICE:
   1. Allow the primer to dry for 3 minutes or more.
   2. Throw away any leftover primer.
   3. Do not apply too much primer.

1. 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.

   Specification:

     Area | Measurement
     a | 7.0 mm (0.276 in.)

4. 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:
      1. Placing matchmarks is only necessary when installing new glass. If it is the reused glass, matchmarks should already be present.
      2. When reusing the glass, check and correct the matchmark positions.

      NOTICE:
        Check that the stoppers are attached to the vehicle body correctly.

   4. Using suction cups, remove the glass.

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

   NOTICE:
   1. Allow the primer to dry for 3 minutes or more.
   2. Do not apply primer to the adhesive.
   3. Throw away any leftover primer.
   4. Do not apply too much primer.

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

   HINT:
     If the primer is applied to an area that is not specified, apply white gasoline to a clean cloth and wipe off the excess primer.

   NOTICE:
   1. Allow the primer to dry for 3 minutes or more.
   2. Throw away any leftover primer.
   3. Do not apply too much primer.

1. 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:

        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.

      Specification:

        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.)

1. 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.

      NOTICE:
      1. Check that the stoppers are attached to the vehicle body correctly.
      2. 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 WINDSHIELD MOULDING OUTER UPPER

1. Using a brush or sponge, apply Primer G to the glass where a new moulding will be installed.

   NOTICE:
   1. Allow the primer to dry for 3 minutes or more.
   2. Throw away any leftover primer.
   3. Do not apply too much primer.

1. Align the moulding's marks with glass notches and install the moulding before the adhesive dries.

   NOTICE:
     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 COWL TOP VENTILATOR LOUVER RH

1. Attach the 4 claws and install the louver.

7. INSTALL COWL TOP VENTILATOR LOUVER LH

1. Attach the 5 claws and install the louver.

8. INSTALL HOOD TO COWL TOP SEAL

1. Attach the 9 clips and install the seal.

9. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH

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

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

1. 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 }

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

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

10. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH

1. Stop the wiper motor at the automatic stop position.

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

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

1. 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 }

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

11. INSTALL FRONT WIPER ARM HEAD CAP

1. Install the 2 caps.

12. INSTALL ROOF HEADLINING ASSEMBLY

For single cab (Click here).
For extra cab (Click here).
For double cab (Click here).

1. Install the roof headlining.

1. Install the No. 1 room light.

1. Install the assist grip.

1. Install the visor holder LH and RH.

1. Install the visor LH and RH.

1. Install the front pillar garnish LH and RH.

1. w/ Pillar assist grip:
   Install the 2 pillar assist grips.

1. Install the front pillar garnish LH and RH.

1. Install the front door opening trim weatherstrip LH and RH.

13. INSTALL INNER REAR VIEW MIRROR ASSEMBLY

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

1. Install the cover as shown in the illustration.

14. CHECK FOR LEAKS AND REPAIR

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

1. Seal any leaks with auto glass sealer.

15. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

16. PERFORM INITIALIZATION

1. Perform initialization (Click here).

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