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Back Window Glass: Replacement

NOTE: The installation is in the reverse order of the removal. However, when there is a special point concerning the installation, it is indicated.
  1. REMOVE REAR SEAT CUSHION ASSY (See step 1 under  OVERHAUL  (TMC Made) or step 1 under  OVERHAUL  (TMMK Made))  .
  2. REMOVE REAR SEAT BACK ASSY (See step 4 under  OVERHAUL  (TMC Made) or step 4 under  OVERHAUL  (TMMK Made)) 
  3. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP RH 
  4. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH 
  5. REMOVE ROOF SIDE GARNISH INNER RH (W/O CURTAIN SHIELD AIR BAG) (See step 27 under  REPLACEMENT  ) 
  6. REMOVE ROOF SIDE GARNISH INNER LH (W/O CURTAIN SHIELD AIR BAG) 
  7. REMOVE ROOF SIDE GARNISH INNER RH (W/ CURTAIN SHIELD AIR BAG) (See step 29 under  REPLACEMENT  ) 
  8. REMOVE ROOF SIDE GARNISH INNER LH (W/ CURTAIN SHIELD AIR BAG) 
  9. REMOVE ROOF HEADLINING ASSY (See step 42 under  REPLACEMENT  ) 
  10. REMOVE CENTER STOP LAMP ASSY (See step 1 under  REPLACEMENT  ) 
  11. REMOVE PACKAGE TRAY TRIM PANEL ASSY (See step 8 under  REPLACEMENT  and step 9 under  REPLACEMENT  ) 
  12. REMOVE BACK WINDOW MOLDING OUTSIDE 
    1. Using a knife, cut off the molding as shown in Fig 1.
      Fig 1: Cutting Off Back Window Molding
      G02823595Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      CAUTION: Do not damage the body with the knife.
    2. Remove the remaining molding.
      NOTE: When removing, make a cut partly, pull and remove it by hand.
  13. REMOVE BACK WINDOW GLASS 
    NOTE: There is a case where a 1-piece type and a 2-piece type of stoppers are installed in a vehicle type.
    Fig 2: Locating 1-Piece And 2-Piece Type Stoppers
    G02823596Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Pass a piano wire through between the body and glass from the interior.
      Fig 3: Identifying Stopper And Piano Wire
      G02823597Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Tie both wire ends to wooden blocks or similar objects.
      NOTE: Apply protective tape to the outer surface to prevent the surface from being scratched.
      CAUTION:
      • When separating the glass, take care not to damage the paint and interior/exterior ornaments.
      • To prevent the piano wire to be cut, do not cross it.
    3. Cut off the adhesive by pulling the piano wire around it.
    4. Using a suction rubber, remove the glass.
    NOTE: Leave as much adhesive on the body as possible when removing the glass.
  14. CLEAN BACK WINDOW GLASS 
    1. Using a scraper, remove the damaged spacers and clips, dam and adhesive sticking to the glass.
      Fig 4: Cleaning Back Window Glass
      G02823598Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Clean the outer circumference of the glass with white gasoline.
    CAUTION:
    • Do not touch the glass after cleaning it.
    • Be careful not to damage the body.
  15. INSTALL BACK WINDOW GLASS STOPPER NO. 1 
    1. Install 2 new windshield glass stoppers No. 1 to the body.
  16. INSTALL BACK WINDOW GLASS STOPPER NO. 2 
    1. Coat the installation part of the stopper with Primer G.
      NOTE:
      • Dry the primer coating for 3 minutes or more.
      • Do not apply too much primer.
    2. Install 2 new windshield glass stoppers No. 2 onto the glass as shown in Fig 5.
      Fig 5: Installing Back Window Glass Stopper No. 2
      G02823599Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      A: 11.2 mm (0.441 in.) 

      B: 40 mm (1.57 in.) 

  17. INSTALL BACK WINDOW GLASS 
    1. Clean and shape the contact surface of the vehicle's body
      1. Using a knife, cut away any rough adhesive on the contact surface of the body to shape the surface.
        NOTE: Leave as much adhesive on the body as possible.
      2. Clean the contact surface of the body with a piece of shop rag saturated with cleaner.
      Fig 6: Cutting Away Rough Adhesive
      G02823600Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Position the glass.
      1. Using a suction rubber, place the glass in the correct position.
      2. Check that the whole contact surface of the glass rim in perfectly even.
      3. Place reference marks between the glass and body.
        CAUTION: Check that the stoppers are attached to the body correctly.
        NOTE: When reusing the glass, check and correct the reference mark's positions.
      4. Remove the glass.
    3. Coat the contact surface of the back door with Primer M.
    4. Using a brush, coat the exposed part of the body on the vehicle side with Primer M.
      NOTE:
      • Dry the primer coating for 3 minutes or more.
      • Do not coat the adhesive with Primer M.
      • Do not apply too much Primer.
    5. Using a brush or sponge, coat the edge of the glass and the contact surface with Primer G.
      CAUTION:
      • Dry the primer coating for 3 minutes or more.
      • Do not apply too much primer.
      NOTE: If the are other than the specified is coated by accident, wipe off the primer with a clean shop rag before it dries.
    6. Apply adhesive.
      1. Cut off the tip of the cartridge nozzle as shown in the illustration.
        Fig 7: Cutting Off Tip Of Cartridge Nozzle
        G02823601Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Part No. 08850-00801 or equivalent 

        NOTE: After cutting off the tip, use all adhesive within the time described in ADHESIVE USAGE TIME REFERENCE .
        ADHESIVE USAGE TIME REFERENCE

        Temperature Tackfree Time
        35° C (95° F) 15 Minutes
        20° C (68° F) 100 Minutes
        5° C (41° F) 8 Hours
      2. Load the sealer gun with the cartridge.
      3. Coat the glass with adhesive, as shown in Fig 7.

        a: 8 mm (0.31 in.) 

        b: 12 mm (0.47 in.) 

        c: 6.5 mm (0.256 in.) 

    7. Install the glass.
      1. Using a suction rubber, position the glass so that the reference marks are aligned, and press it in gently along the rim.
        NOTE:
        • Dry the primer coating for 3 minutes or more.
        • Check that the stoppers are attached to the body correctly.
        • Check the clearance between the body and glass.
      2. Lightly press the glass front surface for close contact.
      3. Using a scraper, remove any excess or protruding adhesive.
        NOTE: Apply adhesive on the glass rim.
  18. INSTALL BACK WINDOW MOLDING OUTSIDE 
    1. Install a new windshield molding to the windshield glass before the adhesive has hardened.
    2. Hold the windshield glass in place securely with protective tape or equivalent until the adhesive has completely hardened.
    3. Using a scraper, remove any excess or protruding adhesive before the adhesive has hardened.
    NOTE: Take care not to drive the vehicle during the time described in DRIVING VEHICLE TIME REFERENCE .
    DRIVING VEHICLE TIME REFERENCE

    Temperature Tackfree Time
    35° C (95° F) 1.5 Hours
    20° C (68° F) 5 Hours
    5° C (41° F) 24 Hours
  19. WATER-LEAK CHECK AND REPAIR 
    1. Conduct a leak test after the adhesive has completely hardened.
    2. Seal any leak with sealant.
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