Body & Frame: Windows: Windshield: Installation

1. Using a knife, cut away any rough areas on the body.

   HINT: Leave as much of the adhesive on the body as possible.

2. Clean the cutting surface of the adhesive with a shop rag saturated in cleaner.

   HINT: Even if all the adhesive has been removed, clean the body.

   Fig 1: Locations Adhesive On Body

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1. Remove the damaged stoppers and dam.
2. Using a scraper, remove the adhesive sticking to the glass.
3. Clean the glass with cleaner.

Fig 2: Cleaning Removed Glass

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1. Remove the damaged stoppers.
2. Cut off the old adhesive around the stopper installation area.
   NOTE: Be careful not to damage the body.
3. Clean the installation area.
4. Attach new stoppers to the body so that the notches on the body will align with the stoppers as shown in the illustration.

   HINT: Make sure that the stoppers are installed facing the correct direction.

   Fig 3: Removing Damaged Stoppers (W/No. 1 Stopper)

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Attach new stoppers to the glass with the ceramic notches on the glass aligned with the stoppers as shown in the illustration.

HINT: Make sure that the stoppers are installed facing the correct direction.

Fig 4: Attaching New Stoppers

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Install a new dam with double-stick tape as shown in the illustration.

A: 7.0 mm (0.276 in.) 

Fig 5: Installing New Dam

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1. Place the glass in the correct position.
2. Check that all contacting parts of the glass rim are perfectly even.
3. Place reference marks between the glass and body.
4. Remove the glass.
   Fig 6: Placing Glass In Correct Position

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Using a cleaner, clean the contact surface which is black-colored area around the entire glass rim.

Fig 7: Cleaning Glass Contact Surface

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Using a brush, coat Primer M to the exposed part of body on the vehicle side.

1. Using a brush or sponge, coat the edge of the glass and the contact surface with Primer G.
2. When the primer is coated wrongly to the area other than the specified, wipe it off with a clean shop rag before the primer dries.

1. Cut off the tip of the cartridge nozzle.

   Part No. 08850-00801 or equivalent 

   HINT: After cutting off the tip, use all adhesive within the time described in the table below.

   ADHESIVE TIME REFERENCE
   
   

   Temperature	Tackfree time
   35 °C (95 °F)	15 minutes
   20 °C (68 °F)	100 minutes
   5 °C (41 °F)	8 hours

   Fig 10: Applying Adhesive

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2. Load the cartridge into the sealer gun.
3. Coat the glass with adhesive as shown in the illustration.

   A: 12 mm (0.47 in.) 

   B: 8 mm (0.31 in.) 

   Fig 11: Coating Glass with Adhesive

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1. Install the glass, aligning the reference marks using a suction rubber.

   HINT: Check that stoppers engage correctly viewing.

2. Lightly press the glass front surface for close contact.
   Fig 12: Aligning Reference Marks

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3. Correct insufficient or protruded adhesive agent using a spatula.

   HINT: Apply the adhesive agent up to the windshield glass edge.

   Fig 13: Applying Adhesive Agent Up To Wind Shield Glass Edge

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4. Install a new windshield outside upper moulding to the windshield glass before the adhesive agent hardens.

   HINT: Install the moulding, aligning the center of moulding with the center of body.

5. Using a scraper, remove any excessive adhesive agent before it hardens.
6. Hold the glass and moulding in place securely with a protective tape or equivalent until the adhesive hardened.
   Fig 14: Installing New Windshield Outside Upper Moulding To Wind Shield Glass

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE: Take care not to drive the vehicle during the time described in the table below.
   TIME REFERENCE
   
   

   Temperature	Minimum time prior to drive of the vehicle
   35 °C (95 °F)	1.5 hours
   20 °C (68 °F)	5 hours
   5°C (41 °F)	24 hours

Attach the upper edge of the weatherstrip to body flange. Tap on the weatherstrip by hand.

Fig 15: Installing Roof Side Rail Weather Strip

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1. Install the 4 screws and windshield outside moulding.
2. Employ the same manner described above to the other side.

Fig 16: Installing Windshield Outside Moulding

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Install the front part of roof side rail weatherstrip LH and RH.

Install the cowl louver with the 8 screws and 6 clips.

1. Operate the wipers once and turn the wiper switch OFF.
2. Install the wiper arms and tighten the nuts by hand.
3. Adjust the installation positions of the wiper arms to the positions shown in the illustration.

   A: Approx. 25.7 mm (1.012 in.) 

   B: Approx. 39.7 mm (1.563 in.) 

   HINT: When installing wiper arms, make sure that the tips of the blades are not beyond the ceramic edge as indicated by "C" part in the illustration.

   Fig 17: Adjusting Installation Positions Of Wiper Arms To Positions

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4. Torque the nuts.

   Torque: 20 N.m (204 kgf.cm, 15 ft.lbf) 

5. Install the caps.

1. Connect the connector.
2. Install the console box with the 4 screws.
   Fig 18: Installing Roof Console Box (W/O Sliding Roof)

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1. Connect the connector.
2. Install the console box with the 2 screws.
   Fig 19: Installing Roof Console Box (W/Sliding Roof)

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1. Connect the connector, then install the front personal light.
2. Install the 2 screws and the clip.

   HINT: When installing the front personal light, attach the clip to the housing and push it to the bracket.

   Fig 20: Installing Front Personal Light

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3. Install the left side lens.
Fig 21: Installing Left Side Lens
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Install the 2 sub-visors with the 4 screws.

1. w/ Light:v
2. Install the 2 sun visors with the 4 screws.

1. Install the front pillar garnish.
2. Employ the same manner described above to the other side.
   Fig 22: Installing Front Pillar Garnish

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1. Driver's side:

   Using a torx socket wrench, install the assist grip with the 2 torx screws.

   Torx driver: T30 (Part No. 09041-00030 or locally manufactured tool) 

2. Standerd cab, Access cab, Passenger side:

   Using a torx driver, install the 2 assist grips with the 4 torx screws.

   Torx driver: T30 (Part No.09041- 00030 or locally manufactured tool) 

3. Double cab cab, Passenger side:

   Using a torx driver, install the assist grips with the 2 torx screws.

   Torx driver: T30 (Part No.09041- 00030 or locally manufactured tool) 

4. Install the caps.
   Fig 23: Installing Assist Grips

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Install the inner rear view mirror as shown in the illustration.

Fig 24: Installing Inner Rear View Mirror

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