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.
Fig 1: Coating Installation Part Of Stoppers With Primer
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

Dimension

AREA MEASUREMENT

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.

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

AREA MEASUREMENT

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

INSTALL WINDSHIELD MOLDING 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 molding.

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 Rough Adhesive Area On Contact Surface Of Vehicle Body
  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.
  
  Fig 5: Placing Marks Between Glass And Vehicle Body
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
  
  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
  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

TEMPERATURE REFERENCE CHART

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

AREA MEASUREMENT

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.

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

Fig 10: Removing Excessive Or Protruding Adhesive

Minimum time

TEMPERATURE REFERENCE CHART

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

CHECK FOR LEAKS AND REPAIR
1. Conduct a leak test after the adhesive has completely hardened.
2. Seal any leaks with auto glass sealer.
  
  Fig 11: Checking Leak And Repair For Adhesive
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002