2008 Lexus ES 350FACTORY OEM SERVICE PROCEDURE

Windshield Glass: Installation

  1. INSTALL NO. 2 WINDSHIELD GLASS STOPPER 
    1. Using a brush or sponge, coat the application area of the No 2 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.

      HINT:

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

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

      HINT:

      Only 2-piece type No. 2 stoppers are supplied. Use the 2-piece type stoppers even if a 1 - piece type was used.

      Standard dimension 

      AREA DIMENSION CHART

      Area Dimension
      A 40 mm (1.574 in.)
      B 20.9 mm (0.822 in.)
      C 10.2 mm (0.401 in.)
      D 23.5 mm (0.925 in.)
      E 12.8 mm (0.503 in.)
      F 10.9 mm (0.429 in.)
      G 19.3 mm (0.759 in.)
      H 47.3 mm (1.862 in.)
      I 17.0 mm (0.669 in.)
      J 42.6 mm (1.677 in.)
      K 12.3 mm (0.484 in.)
      Fig 1: Identifying 2-Piece Type No. 2 Stoppers
      G05253622Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL WINDSHIELD GLASS RETAINER 
    1. Using a brush or sponge, coat the application area of the retainers 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.

      HINT:

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

    2. Install 2 new retainers onto the windshield glass, as shown in the illustration.
      Fig 2: Identifying Retainers Onto Windshield Glass
      G05837961Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL NO. 1 WINDSHIELD GLASS STOPPER 
    1. Install 2 new No. 1 stoppers to the vehicle body, as shown in the illustration.

      HINT:

      Only 2-piece type No. 1 stoppers are supplied. Use the 2-piece type stoppers even if a 1 - piece type was used

      Fig 3: Identifying 2-Piece Type No. 1 Stoppers
      G05837962Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL WINDSHIELD MOULDING OUTSIDE (for Standard) 
    1. Using a brush or sponge, coat the application area of 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.

      HINT:

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

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

      Standard dimension 

      AREA DIMENSION CHART

      Area Dimension
      A 6.4 mm (0.252 in.)
      Fig 4: Identifying Moulding Onto Windshield Glass
      G05253625Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL WINDSHIELD MOULDING OUTSIDE UPPER (for Glass Roof) 
    1. Using a brush or sponge, coat the application area of 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.

      HINT:

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

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

      Standard dimension 

      AREA DIMENSION CHART

      Area Dimension
      A 25.9 mm (1.019 in.)
      Fig 5: Identifying Moulding Onto Windshield Glass
      G05253626Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL WINDSHIELD MOULDING OUTSIDE LH (for Glass Roof) 
    1. Using a brush or sponge, coat the application area of 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.

      HINT:

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

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

      Standard dimension 

      AREA DIMENSION CHART

      Area Dimension
      A 6.4 mm (0.252 in.)
      Fig 6: Identifying Moulding Onto Windshield Glass
      G05253627Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL WINDSHIELD MOULDING OUTSIDE RH (for Glass Roof) 

    HINT:

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

  8. INSTALL WINDOW GLASS ADHESIVE DAM 
    1. Using a brush or sponge, coat the application area of 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.

      HINT:

      If an area other than that 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.
      Fig 7: Identifying Adhesive Dam Onto Windshield Glass
      G05837966Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL WINDSHIELD GLASS ASSEMBLY 
    1. Position the windshield glass assembly.
      1. Using a suction cup, place the windshield glass assembly in the correct position.
      2. Check that the whole contact surface of the windshield glass rim is perfectly even.
      3. Align the matchmarks on the windshield glass and vehicle body.
        NOTE: Check that the windshield glass stoppers are attached to the vehicle body correctly.
      4. Remove the windshield glass assembly.
        Fig 8: Aligning Matchmarks On Windshield Glass And Vehicle Body
        G05253629Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a brush, coat the installation surface on 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.

      HINT:

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

      Standard dimension 

      AREA DIMENSION CHART

      Area Dimension
      A 20.0 mm (0.787 in)
      B 43.7 mm (1.720 in.)
      C 70.2 mm (2.763 in.)
      Fig 9: Coating Installation Surface On Vehicle Body With Primer M
      G05253630Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a brush or sponge, coat the application area of adhesive 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.

      HINT:

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

      Standard dimension 

      AREA DIMENSION CHART

      Area Dimension
      a 8.7 mm (0.342 in.)
      b 12 0 mm (0 472 in.)
      c 28.6 mm (1.126 in.)
      d 12.0 mm (0.472 in.)
      e 8 7 mm (0.342 in.)
      f 12.0 mm (0.472 in.)
      g 12.0 mm (0.472 in.)
      h 6.4 mm (0.252 in.)
      Fig 10: Coating Application Area Of Adhesive With Primer G
      G05253631Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Apply adhesive (Adhesive: TOYOTA genuine windshield glass adhesive 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 described in the table below.

        Usage time frame 

        TEMPERATURE CHART

        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 cartridge.
      3. Apply adhesive to the windshield glass, as shown in the illustration.

        Standard dimension 

        AREA DIMENSION CHART

        Area Dimension
        a 8.7 mm (0.342 in.)
        b 28.6 mm (1.126 in.)
        c 8.7 mm (0.342 in.)
        d 6.4 mm (0.252 in.)
        e 12.0 mm (0.472 in.)
        f 8.0 mm (0.315 in.)
        Fig 11: Applying Adhesive To Windshield Glass
        G05253632Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the windshield glass assembly.
      1. Using a suction cup, position the windshield glass so that the matchmarks are aligned, and press it in gently along the rim
        NOTE:
        • Check that the windshield glass stoppers are attached to the vehicle body correctly.
        • Check the clearance between the vehicle body and windshield glass.
          Fig 12: Installing Windshield Glass Assembly Using Suction Cup
          G05253633Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Lightly press the front surface of the windshield glass to ensure a close fit

        HINT:

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

      3. If necessary, use a scraper to correct the level or position of adhesive that has been applied.

        HINT:

        Apply adhesive onto the windshield glass rim

      4. Hold the windshield glass using protective tape until applied adhesive becomes hard
        NOTE: Do not drive the vehicle for the time described in the table below.
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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.