WINDSHIELD GLASS (for Hatchback): 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: Removing Damaged Stoppers, Dam And Adhesive From 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 Contact Surface Of Vehicle Body

      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: Installing New Stoppers Onto 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 

   WINDSHIELD GLASS STOPPER NO. 2 SPECIFICATION
   
   

   Area	Measurement
   a	40 mm (1.57 In.)
   b	14.5 mm (0.571 In.)

   Fig 4: Installing Windshield Glass Stopper No. 2

   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.

   Specification 

   WINDSHIELD OUTSIDE MOULDING SPECIFICATION
   
   

   Area	Measurement
   a	0.1 mm (0.004 In.)

   Fig 5: Installing Windshield Outside Molding

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Apply Primer G to the installation part of a new dam, as shown in the illustration.
   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 the new dam with double-sided tape as shown in the illustration.

   Specification 

   WINDOW GLASS ADHESIVE DAM SPECIFICATION
   
   

   Area	Measurement
   a	32 mm (1.26 in.)

   Fig 6: Installing Window Glass Adhesive Dam

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Position the windshield glass.
   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.
      Fig 7: Identifying Matchmarks On Windshield Glass And Vehicle Body

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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: Installing Windshield Glass

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Specification 

   WINDSHIELD GLASS SPECIFICATION
   
   

   Area	Measurement
   a	8.0 mm (0.315 In.)
   b	19 mm (0.748 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: 

   Part No. 08850-00801 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 

      WINDSHIELD GLASS TEMPERATURE AND USAGE 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 Cutting Dimension Of Cartridge Nozzle Tip

      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: Identifying Adhesive Applying Area Of Windshield Glass

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Specification 

      WINDSHIELD GLASS SPECIFICATION
      
      

      Area	Measurement
      a	8 mm (0.315 In.)
      b	12 mm (0.472 In.)
      c	10 mm (0.394 In.)
      d	17.5 mm (0.689 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.
   2. Gently press the front surface of the windshield glass to ensure that the windshield glass is securely fitted to the vehicle body.
      Fig 12: Identifying Matchmarks On Windshield Glass And Vehicle Body

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. Using a scraper, remove any excessive or protruding adhesive.

      HINT:

      Apply adhesive to the windshield glass rim.

      NOTE: Do not to drive the vehicle within the time indicated in the table below.
      Fig 13: Removing Excessive Or Protruding Adhesive

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Minimum Time 

      WINDSHIELD GLASS TEMPERATURE AND VEHICLE DRIVING TIMING 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

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

Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 

DIAGNOSIS SYSTEM .