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Back Door Glass: Installation

  1. CLEAN BACK DOOR GLASS 
    1. Using a scraper, remove the clips, dam and adhesive sticking to the back door glass.
    2. Clean the outer edge of the back door glass with a non-residue solvent.
      NOTE:
      • Do not touch the back door glass surface after cleaning it.
      • Even if using a new back door glass, clean the back door glass with a non-residue solvent.
        Fig 1: Cleaning Outer Circumference Of Back Door Glass
        G04833882Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      Since the pin is for positioning the glass, there is no need to replace it with a new one when reusing the glass, even if damaged.

  2. CLEAN VEHICLE BODY 
    1. Clean and shape the contact surface of the vehicle body.
      1. Using a knife, cut away any rough adhesive on the contact surface of the vehicle body to ensure the appropriate surface shape.
        NOTE: Do not damage the vehicle body.

        HINT:

        Leave as much adhesive on the vehicle body as possible.

        Fig 2: Applying Adhesive On Vehicle Body Contact Surface
        G04833862Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Clean the contact surface of the vehicle body with a shop rag or piece of cloth saturated with cleaner.

        HINT:

        Clean the vehicle body even if all the adhesive has been removed.

  3. INSTALL NO. 1 BACK WINDOW GLASS SPACER 
    1. Apply Primer G to the installation part of the No. 1 back window glass spacer.

      HINT:

      If primer is applied to an area that is not specified, wipe off the primer with a non-residue solvent before it dries.

    2. Install the new spacer onto the glass as shown in the illustration.
      NOTE:
      • Allow the primer to dry for 3 minutes or more.
      • Throw away any leftover primer.
      • Do not apply too much primer.
        Fig 3: Applying Primer G To Installation Part Of No. 1 Back Window Glass Spacer
        G05391319Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL NO. 2 BACK WINDOW GLASS SPACER 
    1. Apply Primer G to the installation part of the No. 2 back window glass spacer.

      HINT:

      If primer is applied to an area that is not specified, wipe off the primer with a non-residue solvent before it dries.

    2. Install the new spacer onto the glass as shown in the illustration.
      NOTE:
      • Allow the primer to dry for 3 minutes or more.
      • Throw away any leftover primer.
      • Do not apply too much primer.
      Fig 4: Applying Primer G To Installation Part Of Back Door Glass Adhesive Dam
      G05391320Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL BACK DOOR GLASS ADHESIVE DAM 
    1. Apply Primer G to the installation part of the back door glass adhesive dam.
      NOTE:
      • Allow the primer to dry for 3 minutes or more.
      • Throw away any leftover primer.
      • Do not apply too much primer.

      HINT:

      If primer is applied to an area that is not specified, wipe off the primer with a non-residue solvent before it dries.

    2. Install 2 new back door glass adhesive dams as shown in the illustration.
      Fig 5: Identifying Back Door Glass Adhesive Dams
      G05391321Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Specification 

      BACK DOOR GLASS SPECIFICATION

      Area Measurement
      a 7.0 mm (0.276 in.)
      b 8.5 mm (0.335 in.)
  6. INSTALL BACK WINDOW OUTSIDE MOLDING 
    1. Apply Primer G to the installation part of the back window outside molding.
      NOTE:
      • Allow the primer to dry for 3 minutes or more.
      • Throw away any leftover primer.
      • Do not apply too much primer.

      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.

    2. Install a new back door glass outside molding as shown in the illustration.
      Fig 6: Identifying Back Door Glass Outside Molding
      G05391322Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Specification 

      BACK DOOR GLASS OUTSIDE MOLDING SPECIFICATION

      Area Measurement
      a 4.1 mm (0.161 in.)
  7. INSTALL BACK DOOR GLASS 
    1. Position the back door glass.
      1. Using suction cups, place the back door glass in the correct position.
      2. Check that the whole contact surface of the back door glass rim is perfectly even.
      3. Place matchmarks on the back door glass and vehicle body.
        NOTE: Check that the stoppers are attached to the vehicle body correctly.

        HINT:

        When reusing the back door glass, check and correct the matchmark positions.

      4. Using suction cups, remove the back door glass.
        Fig 7: Placing Matchmarks On Back Door Glass And Vehicle Body
        G05391316Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a brush, apply Primer M to the exposed part of the vehicle body.
      NOTE:
      • Allow the primer to dry for 3 minutes or more.
      • Do not apply Primer M to the adhesive.
      • Throw away any leftover Primer M.
      • Do not apply too much Primer M.
        Fig 8: Applying Primer M To Exposed Part Of Vehicle Body
        G04833927Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a brush or sponge, apply Primer G to the edge of the back door glass and contact surface.
      Fig 9: Identifying Primer G Applying Area
      G05391325Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Allow the primer to dry for 3 minutes or more.
      • Throw away any leftover Primer G.
      • Do not apply too much Primer G.

      HINT:

      If Primer G is applied to any areas other than those specified, wipe off the primer with a clean shop rag or piece of cloth before it dries.

      Specification 

      PRIMER SPECIFICATION

      Area Measurement
      a 11.0 mm (0.433 in.)
      b 50.8 mm (2.000 in.)
      c 11.0 mm (0.433 in.)
    4. Apply adhesive.

      Adhesive: 

      Toyota Genuine Windshield Glass Adhesive or equivalent 

      1. Cut off the tip of the cartridge nozzle, as shown in the illustration.

        HINT:

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

        Usage time frame 

        USAGE TIME FRAME REFERENCE

        Temperature Usage Time Frame
        35°C (95°F) 15 minutes
        20°C (68°F) 1 hour 40 minutes
        5°C (41 °F) 8 hours
        Fig 10: Cutting Off Tip Of Cartridge Nozzle
        G04833929Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Load the sealer gun with the cartridge.
      3. Apply adhesive to the back door glass, as shown in the illustration.
        Fig 11: Identifying Adhesive Applying Area
        G05391327Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Specification 

        CARTRIDGE NOZZLE SPECIFICATION

        Area Measurement
        a 12.0 mm (0.472 in.)
        b 8.0 mm (0.315 in.)
        c 16.3 mm (0.642 in.)
        d 8.0 mm (0.315 in.)
        e 57.8 mm (2.276 in.)
        f 17.7 mm (0.697 in.)
    5. Install the back door glass onto the vehicle body.
      1. Using suction cups, position the back door glass so that the matchmarks are aligned. Press it in gently along the rim.
        NOTE:
        • Allow the primer to dry for 3 minutes or more.
        • Check that the stoppers are attached to the vehicle body correctly.
        • Check that the vehicle body and back door glass have a small gap between them.
      2. Gently press the front surface of the back door glass to ensure that the back door glass is securely fitted to the vehicle body.
        Fig 12: Installing Back Door Glass Onto Vehicle Body
        G05391316Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. Using a scraper, remove any excessive or protruding adhesive.

        HINT:

        Apply adhesive onto the back door glass rim.

        NOTE: Do not to drive the vehicle within the time indicated in the table below.

        Minimum time 

        Fig 13: Removing Any Excessive Or Protruding Adhesive
        G04833932Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        DRIVING VEHICLE TIME PRIOR CHART

        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
  8. CHECK FOR LEAKAGE AND REPAIR 
    1. After the adhesive has hardened, apply water from the outside of the vehicle. Check that no water leaks into the cabin
    2. If water leaks into the cabin, allow the water to dry and add adhesive.
    3. Remove the protective tape.
  9. INSTALL BACK DOOR TRIM UPPER PANEL ASSEMBLY  (See INSTALLATION )
  10. INSTALL BACK DOOR TRIM BOARD ASSEMBLY  (See REASSEMBLY )
  11. INSTALL REAR WIPER ARM AND BLADE ASSEMBLY  (See INSTALLATION )
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