Windshield/Window Glass: 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: Cutting Away Any Rough Areas 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 Glass With Cleaner

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REPLACE NO. 1 STOPPERS 

1. Remove the damaged stoppers.
2. Cut off the old adhesive around the stopper installation area.
   NOTE: Be careful not to damage the body.
   Fig 3: Cutting Off Old Adhesive

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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.

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 To Glass

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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 With Double-Stick Tape

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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: Positioning Glass

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

Fig 7: Cleaning Contact Surface

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

Fig 8: Coating Primer

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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.

Fig 9: Coating Edge Of Glass

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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.

   Diagnostic 

   TEMPERATURE 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 Using Suction Rubber

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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

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

   HINT:

   Install the molding, aligning the center of molding with the center of body.

5. Using a scraper, remove any excessive adhesive agent before it hardens.
6. Hold the glass and molding in place securely with a protective tape or equivalent until the adhesive hardened.

Fig 14: Installing Molding

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

Fig 15: Installing Roof Side Rail Weatherstrip

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

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

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

Fig 16: Installing Cowl Top Ventilator Louver

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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

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4. Torque the nuts.

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

5. Install the caps.

Install the 2 sun visor holders with the 2 screws.

INSTALL ROOF CONSOLE BOX 

1. Connect the connector.
2. Install the console box with the 4 screws.

Fig 18: Installing Roof Console Box

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INSTALL ROOF CONSOLE BOX 

1. Connect the connector.
2. Install the console box with the 2 screws.

Fig 19: Installing Roof Console Box

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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.

Install the 2 sub-visors with the 4 screws.

1. w/ Light:

   Connect the connector.

2. Install the 2 sun visors with the 4 screws.

Fig 21: Installing Sun Visors

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1. Install the front pillar garnish.
2. Perform the same procedure on 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. Standard 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) 

   Fig 23: Installing Assist Grips

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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.

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

Fig 24: Installing Inner Rear View Mirror

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