Windshield Glass: Installation: Installation

Fig 1: Cleaning Outer Circumference Of Back Door Glass

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a scraper, remove the damaged stoppers, dam and adhesive from the windshield glass.
2. Clean the outer circumference of the windshield glass with a non-residue solvent.
   NOTE:

   • Do not touch the windshield glass surface after cleaning it.
   • Even if using a new windshield glass, clean the windshield glass with a non-residue solvent.

Fig 2: Identifying Adhesive On Vehicle Body Contact Surface

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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.
      NOTE:

      Do not damage the vehicle body.

      HINT: 

      Leave as much adhesive on the vehicle body as possible.

   2. Clean the contact surface of the vehicle body with a shop rag or piece of cloth saturated with cleaner.

      HINT: 

      Clean the vehicle body even if all the adhesive has been removed.

Fig 3: Identifying Vehicle Body & Stoppers

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

Fig 4: Identifying Windshield Glass Stopper Ceramic Notch

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Apply Primer G to the installation parts of the stoppers.
   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 stoppers onto the windshield glass, as shown in the illustration.

   Specification

   Area	Measurement
   A	40 mm (1.57 in.)
   B	7.8 mm (0.307 in.)
   C	12.5 mm (0.482 in.)

Fig 5: Installing Windshield Outside Moulding

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a 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.
   • Throw away any leftover Primer G.
2. Install the moulding onto the windshield glass, as shown in the illustration.

1. Apply Primer G to the installation parts of new 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 3 new dams by applying double-sided tape all the way around the windshield glass except where the stoppers are installed, as shown in the illustration.
   Fig 6: Identifying Window Glass Adhesive Dam & Ceramic Notches

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Specification

   Area	Measurement
   a	7.0 mm (0.276 in.)
   b	15.8 mm (0.622 in.)

1. Position the windshield glass.
   Fig 7: Identifying Windshield Glass, Vehicle Body, Matchmarks & Stoppers

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   1. Using suction cups, place the windshield glass in the correct position.
   2. Check that the entire contact surface of the windshield glass rim is perfectly even.
   3. Place matchmarks on the windshield glass and vehicle body.
      NOTE:

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

      HINT: 

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

   4. Using suction cups, remove the windshield glass.
2. Using a brush, apply Primer M to the exposed part of the vehicle body.
   Fig 8: Applying Primer M & Adhesive To Exposed Part Of Vehicle Body

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE:

   • Allow the primer 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 edge of the windshield glass and the contact surface.
   Fig 9: Measurements Of Primer G To Edge Of Windshield Glass & Contact Surface

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Specification

   Area	Measurement
   a	7.8 mm (0.307 in.)
   b	7.8 mm (0.307 in.)
   c	7.0 mm (0.276 in.)
   d	8.0 mm (0.315 in.)

   NOTE:

   • Allow the primer to dry for 3 minutes or more.
   • Throw away any leftover Primer G.
   • Do not apply too much Primer G.

   HINT: 

   If Primer G is applied to any areas other than those specified, wipe off the primer with a clean shop rag or piece of cloth before it dries.

4. Apply adhesive.

   Adhesive

   Toyota Genuine Windshield Glass Adhesive or the equivalent

   1. Cut the tip off the cartridge nozzle, as shown in the illustration.
      Fig 10: Identifying Cutting Dimension Of Cartridge Nozzle Tip

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      After cutting off the tip, use all adhesive within the times indicated 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 windshield glass, as shown in the illustration.
      Fig 11: Identifying Area & Measurement Of Applying Adhesive To Windshield Glass

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Specification

      Area	Measurement
      a	12 mm (0.472 in.)
      b	8 mm (0.315 in.)
      c	3 mm (0.118 in.)
      d	3 mm (0.118 in.)
      e	3 mm (0.118 in.)
      f	11.8 mm (0.465 in.)

5. Install the windshield glass onto the vehicle body.
   Fig 12: Identifying Windshield Glass, Vehicle Body, Matchmarks & Stoppers

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   1. Using suction cups, position the windshield glass so that the matchmarks are aligned. Gently press it in along the rim.
      NOTE:

      • Allow the primer to dry for 3 minutes or more.
      • Check that the stoppers are attached to the vehicle body correctly.
      • Check that there is a small gap between the vehicle body and the windshield glass.
   2. Gently press the front surface of the windshield glass to ensure that the windshield glass is securely fitted to the vehicle body.
   3. Using a scraper, remove any excessive or protruding adhesive.
      Fig 13: Removing Excessive Or Protruding Adhesive Using Scraper

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Apply adhesive to the windshield glass rim.

      NOTE:

      Do not drive the vehicle within the time indicated 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

Fig 14: Identifying Windshield Outside Lower Moulding & Claws

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Engage the 6 claws and install the windshield outside lower moulding.

1. Conduct a leak test by applying water to the adhesive portions after the adhesive has completely hardened.
2. Seal any leakage with auto glass sealer.

Torque: 3.9 N*m (40 kgf*cm, 35 in.*lbf)