TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine BO3E4−02
N21214
Adhesive
BO5231
N06557
Spacer
BO4421
N06558
7 mm (0.28 in.)
− BODYWINDSHIELD
BO−21
1996 TOYOTA T100 (RM449U)
INSTALLATION
1. CLEAN AND SHAPE CONTACT SURFACE OF BODY
(a) Using a knife, cut away any rough areas on the body.
HINT:
Leave as much of the adhesive on the body as possible.
(b) Clean the cutting surface of the adhesive with a piece of
shop rag saturated in cleaner.
HINT:
Even if all the adhesive has been removed, clean the body.
2. CLEAN REMOVED GLASS
(a) Using a scraper, remove the adhesive sticking to the
glass.
(b) Clean the glass with cleaner.
NOTICE:
Do not touch the glass after cleaning it.
3. POSITION GLASS
(a) Place the glass in correct position.
(b) Check that all contacting parts of the glass rim are perfect-
ly even and do not make contact with the spacers.
(c) Place reference marks between the glass and body.
(d) Remove the glass.
4. CLEAN CONTACT SURFACE OF GLASS
Using a cleaner, clean the contact surface black−colored area
around the entire glass rim.
NOTICE:
Do not touch the glass face after cleaning it.
5. INSTALL DAM
Install the dam with double − stick tape as shown in the illustra-
tion.
NOTICE:
Do not touch the glass face after cleaning it.

Downloaded from www.Manualslib.com manuals search engine N00141
Primer M
Adhesive
Primer M Primer M
N06556
Primer G
BO4422
N06484
15 mm
(0.59 in.)
7 mm
(0.28 in.) BO−22
− BODYWINDSHIELD
1996 TOYOTA T100 (RM449U)
6. COAT CONTACT SURFACE OF BODY WITH PRIMER
”M”
Using a brush, coat the contact surface on the body with Primer
M.
NOTICE:
Let the primer coating dry for 3 minutes or more.
Do not coat Primer M to the adhesive.
Do not keep any of the opened Primer M for later use.
7. COAT CONTACT SURFACE OF GLASS WITH PRIMER
”G”
(a) Using a brush or sponge, coat the edge of the glass and
the contact surface with Primer G.
(b) Before the primer dries, wipe it off with a clean shop rag.
NOTICE:
Let the primer coating dry for 3 minutes or more.
Do not keep any of the opened Primer G for later use.
8. MIX ADHESIVE COATING
NOTICE:
Be sure that installation of the moulding is finished
within usable time.
The mixture should be made in 5 minutes or less.
(a) Throughly clean the glass plate and putty spatula with sol-
vent.
(b) Thoroughly mix 500 g (17.64 oz.) of the main agent and
75 g (2.65 oz.) of the hardening agent on a glass plate or
like object with a putty spatula.
9. APPLY ADHESIVE
(a) 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 de-
scribed in the chart below.
TemperatureTackfree time
35°C (95 °F)15 minutes
20°C (68 °F)100 minutes
5°C (41 °F)8 hours
(b) Load the cartridge into the sealer gun.
(c) Coat the glass with adhesive, as shown.

Downloaded from www.Manualslib.com manuals search engine BO2821
BO3986
BO3671
Adhesive
Adhesive
N12568
− BODYWINDSHIELD
BO−23
1996 TOYOTA T100 (RM449U)
10. INSTALL GLASS
(a) Position the glass so that the reference marks are lined
up, and press in gently along the rim.
(b) Using a spatula, apply adhesive on the glass rim.
(c) Use a scraper to remove any excess or protruding adhe-
sive.
(d) Fasten glass securely until the adhesive sets.
NOTICE:
Take care not to drive the vehicle during the time described
in the chart below.
TemperatureMinimum 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
11. INSPECT FOR LEAKS AND REPAIR
(a) Perform a leak test after the hardening time has elapsed.
(b) Seal any leak with sealant.
Part No. 08833−00030 or equivalent
12. APPLY ADHESIVE AT MOULDING INSTALLATION
AREA
Coat the glass with adhesive at the mouldig installation area.
Part No. 08833−00030 or equivalent
13. INSTALL WINDSHIELD UPPER MOULDING
Place the moulding onto the body and tap it by hand.
14. INSTALL WINDSHIELD OUTSIDE MOULDING
15. INSTALL WEATHERSTRIP
16. INSTALL COWL LOUVER
17. INSTALL WIPER ARMS
Torque: 20 N·m (204 kgf·cm, 15 ft·lbf)
18. INSTALL FRONT PILLAR GARNISHES
19. INSTALL ASSIST GRIPS
20. INSTALL SUN VISORS AND HOLDERS

Downloaded from www.Manualslib.com manuals search engine BO−24
− BODYWINDSHIELD
1996 TOYOTA T100 (RM449U)
21. INSTALL INNER REAR VIEW MIRROR

Downloaded from www.Manualslib.com manuals search engine BO0EC−02
N15352
Back Panel Upper Garnish
Back Panel Lower GarnishRear Seat CushionQuarter Window Glass
Back Panel TrimRear Seat
Outer Belt
Front Seat Quarter Trim
Outer Belt
43 (440, 32)
9.8 (100, 7)
43 (440, 32)
43 (440, 32)
43 (440, 32)
N·m (kgf·cm, ft·lbf) : Specifeid torque
9.8 (100, 7)
− BODYQUARTER WINDOW GLASS
BO−25
1909 Author: Date:
1996 TOYOTA T100 (RM449U)
QUARTER WINDOW GLASS
COMPONENTS

Downloaded from www.Manualslib.com manuals search engine BO0ED−03
N13374
10 clips
N13376
N1337711 clips 6 clips BO−26
− BODYQUARTER WINDOW GLASS
1996 TOYOTA T100 (RM449U)
REMOVAL
1. REMOVE FRONT PILLAR GARNISH
2. REMOVE DOOR SCUFF PLATE
3. REMOVE ASSIST GRIP
4. REMOVE BACK PANEL UPPER GARNISH AND BACK
PANEL TRIM
(a) Insert a screwdriver between the back panel upper gar-
nish and body to remove the back panel upper garnish.
HINT:
Tape the screwdriver tip before use.
(b) Remove the 3 bolts and back panel trim.
Torque: 9.8 N·m (100 kgf·cm, 7 in.·lbf)
5. REMOVE REAR SEAT CUSHION
(a) Remove the 3 clips and back panel lower garnishes.
(b) Remove the 2 bolts and rear seat cushion.
Torque: 9.8 N·m (100 kgf·cm, 7 in.·lbf)
6. REMOVE SEAT BELT
Remove the 4 bolts, seat belt anchor and belt guide.
Torque: 43 N·m (440 kgf·cm, 32 ft·lbf)
7. REMOVE LOCK HANDLE
HINT:
Tape a screwdriver tip before use.
(a) Using a screwdriver, remove the cover.
(b) Remove the 2 screws.
8. REMOVE QUARTER TRIM
Remove the 17 clips and quarter trim.

Downloaded from www.Manualslib.com manuals search engine N13378
N13379
− BODYQUARTER WINDOW GLASS
BO−27
1996 TOYOTA T100 (RM449U)
9. REMOVE QUARTER WINDOW GLASS
(a) Remove the 4 nuts and quarter window glass.
(b) Remove the screw and lock handle from the quarter win-
dow glass.
(c) Remove the 2 screws and hinges from the quarter win-
dow glass.

Downloaded from www.Manualslib.com manuals search engine BO0EE−01
BO−28
− BODYQUARTER WINDOW GLASS
1996 TOYOTA T100 (RM449U)
INSTALLATION
Installation is in the reverse order of removal (See page BO−26).

Downloaded from www.Manualslib.com manuals search engine BO0EF−03
Z14390
Weatherstrip
Back WindowBack Window Assembly (Slide Type)
Glass Channel Slide GlassStopperFix Frame
Weatherstrip
− BODYBACK WINDOW GLASS
BO−29
1913 Author: Date:
1996 TOYOTA T100 (RM449U)
BACK WINDOW GLASS
COMPONENTS

Downloaded from www.Manualslib.com manuals search engine BO0EG−03
BO3301
Weatherstrip
Body
Z04539
Weatherstrip BO−30
− BODYBACK WINDOW GLASS
1996 TOYOTA T100 (RM449U)
REMOVAL
REMOVE BACK WINDOW GLASS WITH WINDOW FRAME
HINT:
Tape a screwdriver tip before use.
(a) Using a screwdriver, loosen the weatherstrip from the
body.
NOTICE:
Be careful not to damage the body paint.
(b) Pry the lip of the weatherstrip outward from the interior
part of the body flange.
(c) Pull the glass outwards, and remove it with the weather-
strip.