Windshield Glass: Installation

INSTALL WINDSHIELD GLASS NO. 2 STOPPER

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.

Install 2 new stoppers onto the glass, as shown in the illustration.

Fig 1: Identifying Windshield Glass No. 2 Stopper

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Dimension

DIMENSION

Area	Measurement
A	40.0 mm (1.575 in.)
B	7.7 mm (0.303 in.)

INSTALL WINDSHIELD GLASS NO. 1 STOPPER
1. Install 2 new stoppers to the vehicle body, as shown in the illustration.
  
  Fig 2: Identifying Windshield Glass No. 1 Stopper
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL WINDOW GLASS ADHESIVE DAM

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.

Install a new dam, applying double-sided tape all the way around the glass except where the stoppers are installed, as shown in the illustration.

Fig 3: Identifying Window Glass Adhesive Dam

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Dimension

DIMENSION

Area	Measurement
a	905 mm (0.375 in.)
c	31.4 mm (1.236 in.)

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.

INSTALL WINDSHIELD GLASS

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.
  
  Fig 4: Identifying Area For Applying Adhesive
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
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.
  
  Fig 5: Positioning Glass Using Suction Cup
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  When reusing the glass, check and correct the reference mark positions.
4. Remove the glass.
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
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Apply adhesive (Adhesive: Part No.08850-00801 or equivalent).

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.

Fig 8: Applying Adhesive

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Tackfree time

TACKFREE TIME

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

Load the sealer gun with the cartridge.

Coat the glass with adhesive, as shown in the illustration.

Dimension

DIMENSION

Area	Measurement
a	12.0 mm (0.472 in.)
b	8.0 mm (0.315 in.)
c	3.0 mm (0.118 in.)
d	24.9 mm (0.980 in.)

Install the glass.

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: Positioning Glass Using Suction Cup
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Lightly press the front surface of the glass to ensure a close fit.

Using a scraper, remove any excess or protruding adhesive.

HINT:

Apply adhesive on the glass rim.

Fig 10: Removing Excessive Or Protruding Adhesive

NOTE: Do not drive the vehicle for the amount of time described in the table below.

Minimum time

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 11: Identifying Adhesive Area On Glass Rim

CHECK FOR LEAKS AND REPAIR
1. Conduct a leak test after the adhesive has completely hardened.
2. Seal any leaks with auto glass sealer.