1996 TOYOTA TERCEL Service Repair Manual

BO47Z-01
BO5841
N12299
BO5232
BO1689
BO-34
- BODYWINDSHIELD
1996 TERCEL (RM440U)
REMOVAL
1. REMOVE WIPER ARMS AND COWL LOUVER (See
page BO-27)
2. REMOVE FRONT PILLAR GARNISHES
Remove the garnishes by pulling.
3. REMOVE INNER REAR VIEW MIRROR
Remove the 2 bolts and the inner rear view mirror.
4. REMOVE WINDSHIELD MOULDING
Using a knife, cut off the moulding as shown.
NOTICE:
Do not damage the body with the knife.
5. REMOVE WINDSHIELD GLASS
(a) Push piano wire through between the body and glass
from the interior.
(b) Tie both wire ends to wooden blocks or like object.
HINT:
Apply adhesive tape to the outer surface to keep the surface
from being scratched.
NOTICE:
When separating, take care not to damage the paint and in-
terior and exterior ornaments. To prevent scratching the
safety pad when removing the windshield, place a plastic
sheet between the piano wire and safety pad.
(c) Cut the adhesive by pulling the piano wire around it.
(d) Remove the glass.
NOTICE:
Leave as much of the adhesive on the body as possible
when cutting off the glass.

BO480-01
BO4420
Adhesive
Adhesive
BO5231
BO2820
BO4421
N12582
A, B: 7.0 mm (0.276 in.)
C: 16.0 mm (0.631 in.)A
B
C
A, B and C
- BODYWINDSHIELD
BO-35
1996 TERCEL (RM440U)
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 urethane on the body as possible.
(b) Clean the cutting surface of the urethane gum with a
piece of shop rag saturated in cleaner.
HINT:
Even if all the urethane has been removed, clean the body.
2. CLEAN REMOVED GLASS BEFORE INSTALLATION
(a) Using a scraper, remove the urethane gum sticking to the
glass.
(b) Clean the glass with cleaner.
NOTICE:
Do not touch the glass after cleaning it.
3. POSITION GLASS
(a) Place glass in correct position.
(b) Check that all contacting parts of the glass rim are perfect-
ly even.
(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 which is black-col-
ored 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.

N00141
Primer MPrimer M
Primer M
Adhesive
Z16244
Primer G
Primer G
BO4422
N11279
H BO-36
- BODYWINDSHIELD
1996 TERCEL (RM440U)
6. COAT CONTACT SURFACE OF BODY WITH PRIMER
ºMº
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
ºGº
(a) Using a brush or sponge, coat the edge of the glass and
the contact surface with Primer G.
(b) Wipe it off with a clean shop rag before the primer dries.
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 glass is finished within
usable time.

The mixture should be made in 5 minutes or less.
(a) Thoroughly clean the glass plate and putty spatula with
solvent.
(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 to make a hole 5 mm
(0.20 in.) in diameter. Fill the cartridge with adhesive.
(b) Load the cartridge into the sealer gun.
(c) Coat the glass with adhesive on all contact surfaces along
the ridge.
Adhesive height:
If adhesive remains on body:
H: 3.5 - 5.0 mm (0.138 - 0.197 in.)
If no adhesive remains on body :
H: 8 - 10 mm (0.31 - 0.39 in.)

BO2821
BO3671
Adhesive
Adhesive
N12300
- BODYWINDSHIELD
BO-37
1996 TERCEL (RM440U)
10. INSTALL GLASS
HINT:
Confirm that the dam is attached the body panel as shown in
the illustration.
(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 spatula to remove any excess or protruding adhe-
sive.
(d) Fasten glass securely until the adhesive sets.
11. INSPECT FOR LEAKS AND REPAIR
(a) Perform a leak test after the hardening time has elapsed.
(b) Seal any leaks with sealant.
Part No. 08833-00030 or equivalent.
12. INSTALL WINDSHIELD MOULDING
(a) Using a knife, cut off the adhesive around the moulding
installation area.
(b) Apply adhesive at moulding installation area.
(c) Place the moulding onto the body and tap it by hand.
13. INSTALL COWL LOUVER AND WIPER ARMS (See
page BO-26)
14. INSTALL INNER REAR VIEW MIRROR
15. INSTALL FRONT PILLAR GARNISH
16. INSTALL COWL LOUVER
17. INSTALL WIPER ARMS

BO1I3-02
N15578
Rear Seatback
Rear Seat Cushion
Front Seat
Outer Belt
Front Door Scuff PlatePackage Tray Trim Side Cover
Rear Seat Outer Belt
Roof Side Inner Garnish
Quarter Trim Board
Quarter Window Glass
BO-38
- BODYQUARTER WINDOW GLASS
1132 Author
: Date
:
1996 TERCEL (RM440U)
QUARTER WINDOW GLASS
COMPONENTS

BO342-01
Z16117
: 4 Clips
Z16118
: 2 Clips
: 5 Clips
N12584
N12581
N12585
- BODYQUARTER WINDOW GLASS
BO-39
1996 TERCEL (RM440U)
REMOVAL
1. REMOVE REAR SEAT CUSHION
2. REMOVE REAR SEATBACK
3. REMOVE FRONT SEAT OUTER BELT
4. REMOVE PACKAGE TRAY TRIM SIDE COVER
5. REMOVE REAR SEAT OUTER BELT
6. REMOVE QUARTER TRIM BOARD
7. REMOVE FRONT DOOR SCUFF PLATE
8. REMOVE ROOF SIDE INNER GARNISH
9. REMOVE QUARTER WINDOW GLASS
(a) Push piano wire through between body and glass from
the interior.
(b) Tie both wire ends to wooden blocks or similar object.
HINT:
Apply adhesive tape to the outer surface to keep the surface
from being scratched.
NOTICE:
When separating the glass, take care not to damage the
paint and exterior.
(c) Cut the adhesive by pulling the piano wire around it.
HINT:
Cut the adhesive areas as shown in the illustration, leaving the
adhesive where the pins are.
(d) Using piano wire, as shown in the illustration, cut off the
rest of the adhesive.
(e) Remove the glass.
NOTICE:
Leave as much of the adhesive on the body as possible
when cutting off the glass.

BO343-01
BO4420
AdhesiveAdhesive
N00141
Adhesive Primer M
Primer M
Primer M
Z16119
Primer G
Primer G
BO4422
BO-40
- BODYQUARTER WINDOW GLASS
1996 TERCEL (RM440U)
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 BEFORE INSTALLATION
(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. COAT CONTACT SURFACE OF BODY WITH PRIMER
ºMº
Using a brush, coat the contact 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.
4. COAT CONTACT SURFACE OF GLASS WITH PRIMER
ºGº
(a) Using a brush or sponge, coat the edge of the glass and
the contact surface with Primer G.
(b) Wipe it off with a clean shop rag before the primer dries.
NOTICE:

Let the primer coating dry for 3 minutes or more.

Do not keep any of the opened Primer G for later use.
5. MIX ADHESIVE COATING
NOTICE:
Be sure that installation of the moulding is finished within
the adhesive's usable time.
(a) Thoroughly clean the glass plate and putty spatula with
solvent.
(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
similar object with a putty spatula.

N12283
a - a b - bab
H ab
H
- BODYQUARTER WINDOW GLASS
BO-41
1996 TERCEL (RM440U)
6. APPLY ADHESIVE
(a) Cut off the tip of the cartridge nozzle. Fill the cartridge with
adhesive.
(b) Load the cartridge into the sealer gun.
(c) Coat the glass with adhesive, as shown.
H: 12 mm (0.47 in.)
7. INSTALL QUARTER WINDOW GLASS
(a) Install the glass to the body.
(b) Use adhesive tape to keep the glass tight against the
body.
8. 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.
9. INSTALL ROOF SIDE INNER GARNISH
10. INSTALL FRONT DOOR SCUFF PLATE
11. INSTALL QUARTER TRIM BOARD
12. INSTALL REAR SEAT OUTER BELT
Torque: 43 N´m (440 kgf´cm, 32 ft´lbf)
13. INSTALL PACKAGE TRAY TRIM SIDE COVER
14. INSTALL FRONT SEAT OUTER BELT
Torque: 43 N´m (440 kgf´cm, 32 ft´lbf)
15. INSTALL REAR SEAT BECK
Torque: 18 N´m (185 kgf´cm, 13 ft´lbf)
16. INSTALL REAR SEAT CUSHION