Toyota 4Runner: Installation

INSTALLATION

PROCEDURE

1. INSTALL NO. 1 WINDSHIELD GLASS STOPPER

(a) Install 2 new No. 1 windshield glass stoppers to the vehicle body as shown in the illustration. Text in Illustration *1 No. 1 Windshield Glass Stopper *2 Vehicle Body

2. INSTALL NO. 2 WINDSHIELD GLASS STOPPER

(a) Apply Primer G to the windshield glass where the No. 2 windshield glass stoppers will be installed.

(b) Install 2 new No. 2 windshield glass stoppers to the windshield glass at the locations shown in the illustration.

Text in Illustration

*1	Windshield Glass	*2	No. 2 Windshield Glass Stopper
*a	Backside	*b	Ceramic Notch
*c	Ceramic Line	d	Center

Standard:

Area	Specified Condition
a	14.2 mm (0.559 in.)

3. INSTALL WINDSHIELD OUTSIDE UPPER MOULDING

(a) Using a brush or sponge, coat the contact surface of the windshield glass and windshield outside upper moulding with Primer G as shown in the illustration.

Text in Illustration

*1	Windshield Outside Upper Moulding	-	-
*a	Backside	-	-

Standard:

Area	Specified Condition
a	6.9 mm (0.272 in.)

(b) Remove the peeling paper from a new windshield outside upper moulding. Install the windshield outside upper moulding as shown in the illustration.

4. INSTALL WINDSHIELD GLASS ADHESIVE DAM

(a) Apply Primer G to the windshield glass where the windshield glass adhesive dam will be installed.

(b) Remove the peeling paper from the adhesive part of a new windshield glass adhesive dam. Install the windshield glass adhesive dam (adhesive side) to the windshield glass (Primer G area), but exclude the area above the notches on the upper part of the windshield glass.

Text in Illustration

*a	Backside	*b	Ceramic Notch
*c	Dam Center Line	-	-

Standard:

Area	Specified Condition
a	9.5 mm (0.374 in.)
b	37.7 mm (1.48 in.)

5. INSTALL WINDSHIELD GLASS

(a) Position the windshield glass. (1) Using suction cups, place the windshield glass in the correct position. (2) Check that the entire contact surface of the windshield glass rim is perfectly even. (3) Place matchmarks on the windshield glass and vehicle body at the locations indicated in the illustration. Text in Illustration *a Matchmark NOTICE: Check that the stoppers are attached to the vehicle body correctly. HINT: Placing matchmarks is only necessary when installing new windshield glass. When reinstalling the used windshield glass, matchmarks should already be present. When reusing the windshield glass, check and correct the matchmark positions. (4) Using suction cups, remove the windshield glass.

(b) Using a brush, apply Primer M to the exposed part of the vehicle body.

Text in Illustration

*a	CORRECT
*b	INCORRECT
	Primer M
	Adhesive

(c) Using a brush or sponge, apply Primer G to the contact surface of the windshield glass.

Text in Illustration

*a	Backside	*b	Adhesive Center Line
	Primer M	-	-

Standard:

Area	Specified Condition
a	9.5 mm (0.374 in.)
b	3.0 mm (0.118 in.)
c	8.0 mm (0.315 in.)
d	28.1 mm (1.11 in.)
e	7.0 mm (0.276 in.)

HINT:

If the primer is applied to an area that is not specified, apply non-residue solvent to a clean cloth and wipe off the excess primer before it dries.

(d) Apply adhesive to the windshield glass.

Adhesive:

Toyota Genuine Windshield Glass Adhesive or equivalent

(1) Cut off the tip of a cartridge nozzle as shown in the illustration.

HINT:

After cutting off the tip, use all adhesive within the time written in the table below.

Usage Time Frame:

Temperature	Usage Time Frame
35°C (95°F)	15 minutes
20°C (68°F)	1 hour 40 minutes
5°C (41°F)	8 hours

(2) Load a sealer gun with the cartridge.

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

Text in Illustration

*a	Backside	*b	Adhesive Center Line
	Adhesive	-	-

Standard:

Area	Specified Condition
a	12.0 mm (0.472 in.)
b	8.0 mm (0.315 in.)
c	9.5 mm (0.374 in.)
d	3.0 mm (0.118 in.)

(e) Install the windshield glass to the vehicle body.

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

Text in Illustration

*a

Matchmark

(2) Lightly press the outer surface of the windshield glass to ensure that it is securely fit to the vehicle body.

(3) If necessary, use a scraper to correct the level or position of adhesive that has been applied. Text in Illustration *1 Windshield Glass Adhesive Dam *2 Adhesive *3 Windshield Glass HINT: Apply adhesive to any areas where the amount of adhesive is inadequate.

(4) Hold the windshield glass in place securely with protective tape or equivalent until the adhesive hardens.

NOTICE:

Do not drive the vehicle within the amount of time written in the table below.

Minimum Time:

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

(f) w/ Windshield Deicer System:

Connect the windshield deicer connector.

6. INSTALL WINDSHIELD OUTSIDE MOULDING

(a) Using a brush or sponge, apply Primer G to the windshield glass where the windshield outside moulding will be installed.

HINT:

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

(b) Apply Primer G to the windshield outside moulding area "a" shown in the illustration.

(c) Install a new windshield outside moulding to the windshield glass as shown in the illustration.

7. CHECK FOR LEAK AND REPAIR

(a) Conduct a leak test after the adhesive has completely hardened.

(b) Seal any leaks with auto glass sealer.

8. INSTALL ROOF HEADLINING ASSEMBLY

(a) Return the roof headlining assembly to its original position. Refer to the following procedures (See page ).

9. INSTALL INNER REAR VIEW MIRROR ASSEMBLY (w/ EC Mirror)

10. INSTALL INNER REAR VIEW MIRROR STAY HOLDER COVER (w/ EC Mirror)

11. INSTALL INNER REAR VIEW MIRROR ASSEMBLY (w/o EC Mirror)

12. INSTALL MAP LIGHT ASSEMBLY

13. INSTALL DRIVE MONITOR SWITCH (w/ Drive Monitor Switch)

14. INSTALL VISOR HOLDER

15. INSTALL VISOR ASSEMBLY LH

16. INSTALL VISOR ASSEMBLY RH

HINT:

Use the same procedure as for the LH side.

17. INSTALL VISOR BRACKET COVER LH

18. INSTALL VISOR BRACKET COVER RH

HINT:

Use the same procedure as for the LH side.

19. INSTALL ASSIST GRIP SUB-ASSEMBLY

20. INSTALL FRONT PILLAR GARNISH LH

21. INSTALL FRONT PILLAR GARNISH RH

22. INSTALL NO. 1 ASSIST GRIP

23. INSTALL ASSIST GRIP PLUG

24. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP LH

25. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP RH

HINT:

Use the same procedure as for the LH side.

26. INSTALL COWL SIDE TRIM BOARD LH

27. INSTALL COWL SIDE TRIM BOARD RH

HINT:

Use the same procedure as for the LH side.

28. INSTALL DOOR SCUFF PLATE ASSEMBLY LH

29. INSTALL DOOR SCUFF PLATE ASSEMBLY RH

HINT:

Use the same procedure as for the LH side.

30. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

31. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH

32. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH

33. INSTALL FRONT WIPER ARM HEAD CAP

34. INSTALL FRONT FENDER TO COWL SIDE SEAL LH

35. INSTALL FRONT FENDER TO COWL SIDE SEAL RH

HINT:

Use the same procedure as for the LH side.

36. INSTALL FRONT FENDER MAIN SEAL LH

37. INSTALL FRONT FENDER MAIN SEAL RH

HINT:

Use the same procedure as for the LH side.

38. INSTALL UPPER RADIATOR SUPPORT SEAL

39. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

NOTICE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected (See page ).