Windshield Glass: Installation

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 1: Cleaning Windshield Glass

     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.

      Fig 2: Identifying Adhesive On Vehicle Body Contact Surface

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   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.

1. Install 2 new stoppers onto the vehicle body, as shown in the illustration.
   Fig 3: Identifying Stoppers On Vehicle Body

   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 

   SPECIFICATION
   
   

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

   Fig 4: Identifying Windshield Glass Area Measurement

   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.

Fig 5: Identifying Moulding Onto Windshield Glass

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Specification 

   SPECIFICATION
   
   

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

1. Position the windshield glass.
   1. Using suction cups, place the windshield glass in the correct position.
   Fig 7: Installing Windshield Glass Using Suction Cups
   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   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.
   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.

   Fig 8: Applying Primer M To Exposed Part Of Vehicle Body

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a brush or sponge, apply Primer G to the edge of the windshield glass and the contact surface.
   Fig 9: Applying Primer G To Edge Of Windshield Glass & Contact Surface

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Specification 

   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.

      HINT:

      After cutting off the tip, use all adhesive within the times indicated in the table below.

      Usage time frame 

      TIME FRAME REFERENCE
      
      

      Temperature	Usage Time Frame
      35°C (95°F)	15 minutes
      20°C (68°F)	1 hour 40 minutes
      5°C (41°F)	8 hours

      Fig 10: Identifying Cartridge Nozzle Cutting Dimensions

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Load the sealer gun with the cartridge.
   3. Apply adhesive to the windshield glass, as shown in the illustration.
      Fig 11: Applying Adhesive To Windshield Glass

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Specification 

      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.
   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.

      Fig 12: Positioning Windshield Glass

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   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.

      HINT:

      Apply adhesive to the windshield glass rim.

      NOTE: Do not drive the vehicle within the time indicated in the table below.

      Minimum time 

      MINIMUM TIME REFERENCE
      
      

      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 13: Removing Excessive Or Protruding Adhesive

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

Fig 14: Identifying Claws For Windshield Outside Lower Moulding

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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)