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Windshield Glass: Installation

  1. INSTALL WINDSHIELD GLASS NO. 2 STOPPER 
    1. Coat the installation part of the stoppers 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 stoppers onto the glass, as shown in Fig 1 .
      Fig 1: Installing Stoppers Onto Glass
      G04495676Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Dimension 

      STOPPERS INSTALLING DIMENSION

      Area Measurement
      A 40.0 mm (1.575 in.)
      B 7.7 mm (0.303 in.)
  2. INSTALL WINDSHIELD GLASS NO. 1 STOPPER 
    1. Install 2 new stoppers to the vehicle body, as shown in Fig 2 .
    Fig 2: Installing Stoppers To Vehicle Body
    G04495677Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL WINDOW GLASS ADHESIVE DAM 
    1. Coat the installation part of the windshield glass adhesive 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 stoppers are installed, as shown in Fig 3 .
      Fig 3: Installing Window Glass Adhesive Dam
      G04495678Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Dimension 

      ADHESIVE DAM INSTALLING DIMENSION

      Area Measurement
      a 7.0 mm (0.276 in.)
      b 6.0 mm (0.236 in.)
      c 35.0 mm (1.378 in.)
  4. INSTALL WINDSHIELD MOULDING OUTER UPPER 
    1. Using the 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 moulding.
  5. 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.

        HINT:

        Leave as much of the adhesive on the vehicle body as possible.

      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.

        Fig 4: Cleaning And Shaping Contact Surface
        G04495679Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.

      4. Remove the glass.
        Fig 5: Positioning Glass
        G04495680Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a brush, coat the exposed part of the vehicle body 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 6: Coating Exposed Part Of Vehicle Body With Primer M Using Brush
      G04495681Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using a brush or sponge, coat the edge of the glass and the contact surface with Primer G.

      HINT:

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

      NOTE:
      • Allow the primer coating to dry for 3 minutes or more.
      • Do not keep any of the opened Primer G for later use.
      Fig 7: Coating Edge Of Glass And Contact Surface With Primer G
      G04495682Courtesy 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 Fig 8 .

        HINT:

        After cutting off the tip, use all adhesive within the time described in TACK FREE TIME REFERENCE  .

        Fig 8: Cutting Off Tip Of Cartridge Nozzle
        G04495683Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Tack free time 

        TACK FREE TIME REFERENCE

        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. Coat the glass with adhesive, as shown in Fig 8 .

        Dimension 

        ADHESIVE APPLYING DIMENSIONS

        Area Measurement
        a 12.0 mm (0.472 in.)
        b 8.0 mm (0.315 in.)
        c 3.0 mm (0.118 in.)
        d 40.0 mm (1.575 in.)
    6. Install the glass.
      1. Using a suction cup, position the glass so that the reference marks are aligned. 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 that clearance between the vehicle body and glass.
        Fig 9: Installing Glass
        G04495684Courtesy 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.

        HINT:

        Fig 10: Removing Any Excess Or Protruding Adhesive Using Scraper
        G04495685Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Apply adhesive on the glass rim.

        Fig 11: Applying Adhesive On Glass Rim
        G04495686Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        NOTE: Do not drive the vehicle for the amount of time described in MINIMUM TIME REFERENCE FOR DRIVING VEHICLE  .

        Minimum time 

        MINIMUM TIME REFERENCE FOR DRIVING VEHICLE

        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. REMOVE WINDSHIELD MOULDING OUTSIDE LH 
  7. INSTALL WINDSHIELD MOULDING OUTSIDE RH 
  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 COWL TOP VENTILATOR LOUVER SUBASSEMBLY 
  10. INSTALL FRONT WIPER ARM RH 
  11. INSTALL FRONT WIPER ARM LH 
  12. REMOVE FRONT WIPER ARM HEAD CAP 
  13. INSTALL ROOF HEADLINING ASSEMBLY 
  14. INSTALL INNER REAR VIEW MIRROR ASSEMBLY 
  15. REMOVE SUN ROOF OPENING TRIM MOULDING (W/ SLIDING ROOF) 
  16. INSTALL ROOF CONSOLE BOX ASSEMBLY 
  17. INSTALL VISOR HOLDER 
  18. INSTALL ASSIST GRIP SUB-ASSEMBLY 
  19. INSTALL VISOR ASSEMBLY RH 
  20. INSTALL VISOR ASSEMBLY LH 
  21. INSTALL FRONT PILLAR GARNISH RH 
  22. INSTALL FRONT PILLAR GARNISH LH 
  23. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP RH 
  24. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP LH 
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