WINDSHIELD GLASS INSTALLATION

CAUTION / NOTICE / HINT

Tech Tips

Use the same procedure for the LHD and RHD vehicle.

PROCEDURE


  1. INSTALL NO. 1 WINDSHIELD GLASS STOPPER


    1. Apply primer (Sunstar #435-70) to the glass attachment surface of the No. 1 windshield glass stopper.

    2. Apply primer (Sunstar #435-40) to the new No. 1 windshield glass stopper attachment surface of the windshield glass.

      Note


      • Do not apply too much primer.

      • After applying the primer for the locate pin, and dry for at least 10 minute.

    3. After drying the primer, apply adhesive (Sunstar # 560) to the No. 1 windshield glass stopper attachment surface.

    4. A004J9UE02
      Text in Illustration
      *1 Attachment Holes
      *2 No. 1 Windshield Glass Stopper
      *a Back Side
      A004K5G Primer
      A004H2J Adhesive

      Install the No. 1 windshield glass stopper to the attachment holes.

  2. INSTALL NO. 2 WINDSHIELD GLASS STOPPER

    Tech Tips

    Use the same procedure for both the No. 1 windshield glass stopper.

  3. INSTALL WINDSHIELD OUTSIDE MOULDING


    1. A004KU1E02
      Text in Illustration
      *a Back Side
      *b Application Area

      Using a brush, apply primer (Sunstar GP402) to the windshield outside moulding attachment surface of the windshield glass and the windshield glass outer ends.

      Note

      Do not apply primer out of the ceramic areas.

    2. After drying the primer, match the new windshield outside moulding to both edges of the windshield glass.

    3. A004IUAE01
      Text in Illustration
      *a Back Side

      Using a roller, crimp the windshield outside moulding in the direction of the arrows, as shown in the illustration.

      Standard
      50 N/100 mm (5.1 kgf/100 mm, 11.2 lbf/100 mm)

      Note

      Install the windshield outside moulding firmly so that it does not sag

    4. A004IMFE01
      Text in Illustration
      *a Back Side

      Using a roller, crimp the windshield outside moulding in the direction of the arrows, as shown in the illustration.

      Standard
      50 N/100 mm (5.1 kgf/100 mm, 11.2 lbf/100 mm)

      Note

      Install the windshield outside moulding firmly so that it does not sag

  4. INSTALL UPPER WINDSHIELD GLASS SEAL


    1. Remove the release paper from the upper windshield glass seal.

      Tech Tips

      After removing the release paper, keep the exposed adhesive free from foreign matter.

    2. A004IY8E01
      Text in Illustration
      *1 Windshield Outside Moulding
      *a Back Side
      A004H2J Upper Windshield Glass Seal

      Install the upper windshield glass seal to the windshield outside moulding, as shown in the illustration.

      Standard Dimension
      Area Dimension
      a 165 mm (6.4961 in.)
      b 3.0 mm (0.1181 in.)
      c 5.7mm (0.2244 in.)
      d 5.0 mm (0.1969 in.)
      e 0 to 0.5 mm (0 to 0.0197 in.)

  5. INSTALL WINDOW GLASS ADHESIVE DAM


    1. Install the new window glass adhesive dam onto the windshield glass, as shown in the illustration.

      A004J39E02
      Standard Dimension
      Area Dimension
      a 13.0 mm (0.5118 in.)
      b 15.3 mm (0.6024 in.)
      c 0 to 3.0mm (0 to 0.1181 in.)
      d 14.8 mm (0.5827 in.)
      Text in Illustration
      *1 Ceramic Notch *2 Window Glass Adhesive Dam
      *a Back Side - -

      Tech Tips

      Use the same procedure for both the RH and LH sides.

  6. INSTALL LOWER WINDSHIELD GLASS SEAL


    1. Install the new lower windshield glass seal onto the windshield glass, as shown in the illustration.

      A004JZ7E02
      Standard Dimension
      Area Dimension
      a 28.0 mm (1.1024 in.)
      Text in Illustration
      *1 Ceramic Notch *2 Lower Windshield Glass Seal
      *3 Window Glass Adhesive Dam - -
      *a Back Side - -

      Tech Tips

      Use the same procedure for both the RH and LH sides.

  7. INSTALL WINDSHIELD GLASS


    1. Position the windshield glass.


      1. Using suction cups, place the windshield glass in the correct position.

      2. A004KTLE02
        Text in Illustration
        *1 Windshield Glass
        *2 Body

        Check that the whole contact surface of the windshield rim is perfectly even.

        Standard Dimension
        Area Dimension
        a 4.0 mm (0.1575 in.)
        b 5.0 mm (0.1969 in.)
      3. A004JP1E02
        Text in Illustration
        *a Matchmark

        Align the matchmarks on the windshield glass and vehicle body.

        Note

        Check that the windshield glass stopper are attached to the vehicle body correctly.

      4. Remove the windshield glass .

    2. A004HPGE01
      Text in Illustration
      *a NG
      *b OK
      A004K5G Primer
      A004H2J Adhesive

      Using a brush, coat the installation surface on the vehicle body with Primer.

      Sunstar
      Enclosed with penguin seal #580 super.
      Yokohama
      M-300 or equivalent

      Note


      • Do not coat the adhesive with Primer.

      • Do not apply too much primer.

      Tech Tips

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

    3. Using a brush or sponge, coat the application area of adhesive with Primer.

      Sunstar
      Enclosed with penguin seal #580 super.
      Yokohama
      M-300 or equivalent
      A004IJEE01
      Standard Dimension
      Area Dimension
      a 8.0 mm (0.315 in.)
      Text in Illustration
      *a Back Side - -
      A004H2J Primer - -

      Note


      • Do not apply too much primer.

      • Allow the primer to dry for 3 minutes or more.

      Tech Tips

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

    4. Apply adhesive to the glass.

      Adhesive
      Toyota Genuine Windshield Glass Adhesive or equivalent

      1. A004KIHE01
        Text in Illustration
        *a Back Side - -
        A004H2J Adhesive - -

        Cut off the tip of the cartridge nozzle, as shown in the illustration.

        Standard Dimension
        Area Dimension
        a 9.0 mm (0.354 in.)
        b 8.0 mm (0.315 in.)

      2. Load the sealer gun with cartridge.

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

        A004IFPE01
        Standard Dimension
        Area Dimension
        a 2.0 mm (0.0787 in.)
        b 8.0 mm (0.3150 in.)
        c 9.0 mm (0.3543 in.)
        d 11.3 mm (0.4449 in.)
        e 22.0 mm (0.8661 in.)
        f 30.0 mm (1.1811 in.)
        g 10.8 mm (0.4252 in.)

        Tech Tips

        Apply adhesive keep to the window glass adhesive dam.

    5. A004JP1E02
      Text in Illustration
      *a Matchmark

      Apply adhesive tape, etc. to the windshield glass and the body panel section, and use a pen to apply matching marks for use when installing (when using the new windshield glass).


      1. Using suction cups, position the windshield glass so that the matchmarks are aligned, and press it in gently along the rim.

        Note


        • Check that the windshield glass stopper are attached to the vehicle body correctly.

        • Check the clearance between the vehicle body and windshield glass.

        • After the primer on the body is dried (about 10 minutes), install the windshield glass.

      2. Lightly press the front surface of the windshield glass to ensure that the windshield glass is securely fit to the vehicle body.

        Tech Tips

        Press the glass with a force of 98 N (10 kgf, 22.0 lbf) or more.

      3. Using a scraper, remove any excess or protruding adhesive.

        Tech Tips

        Apply adhesive onto the windshield glass rim.

      4. Hold the windshield glass using protective tape until the applied adhesive becomes hard.

        Tech Tips

        Follow the instructions in the owner's manuals provided by each adhesive manufacturer regarding the minimum required drying time after applying adhesive, and the time required before driving.

  8. INSPECT WATER LEAK


    1. After the adhesive has hardened, apply water from the outside of the vehicle. Check that no water leaks into the cabin.

    2. If water leaks into the cabin, allow the water to dry and add adhesive.

    3. Remove the protective tape.

  9. INSTALL ROOF HEADLINING ASSEMBLY

    Click here

  10. INSTALL COWL VENTILATOR LOUVER

    Click here

  11. INSTALL FRONT FENDER TO COWL SIDE SEAL RH

    Click here

  12. INSTALL FRONT FENDER TO COWL SIDE SEAL LH

    Tech Tips

    Use the same procedure as for the RH side.

  13. INSTALL WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH

    Click here

  14. INSTALL WINDSHIELD WIPER ARM AND BLADE ASSEMBLY RH

    Click here

  15. INSTALL WINDSHIELD WIPER ARM COVER

    Click here