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Back Door 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 ASSIST STRAP HOLE COVER (See step 4 under  OVERHAUL  ) 
  2. REMOVE ASSIST STRAP ASSY RH (See step 4 under  OVERHAUL  ) 
  3. REMOVE BACK DOOR TRIM PANEL ASSY (See step 4 under  OVERHAUL  ) 
  4. REMOVE BACK WINDOW PANEL TRIM UPPER (See step 1 under  OVERHAUL  ) 
  5. REMOVE BACK DOOR TRIM COVER RH (See step 2 under  OVERHAUL  ) 
  6. REMOVE BACK DOOR TRIM COVER LH 
  7. REMOVE REAR WIPER ARM ASSY (See  REAR WIPER ARM ASSY  ) 
  8. REMOVE REAR SPOILER (W/ REAR SPOILER) (See step 2 under  REPLACEMENT  ) 
  9. REMOVE BACK DOOR GLASS 
    1. Disconnect the connector.
      Fig 1: Identifying Back Door Glass Spacer
      G02859653Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Pass a piano wire through between the back door and glass from the interior.
    3. Tie both wire ends to wooden blocks or similar objects.
      NOTE: Apply protective tape to the outer surface to keep the surface from being scratched.
      CAUTION: When separating the glass, take care not to damage the paint and interior exterior ornaments.
    4. Cut the adhesive by pulling the piano wire around it.
      Fig 2: Identifying Areas For Cutting Adhesive
      G02859654Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the glass.
      NOTE: Leave as much adhesive on the body as possible when cutting off the glass.
  10. CLEAN BACK DOOR GLASS 
    1. Using a scraper, remove the damaged stoppers, dam and adhesive sticking to the glass.
      Fig 3: Cleaning Glass With Cleaner Or White Gasoline
      G02859655Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Clean the glass with cleaner or white gasoline.
      NOTE:
      • Do not touch the glass after cleaning it.
      • Be careful not to damage the body.
  11. INSTALL BACK DOOR GLASS SPACER NO. 1 
    1. Remove the damaged spacer.
      Fig 4: Installing New Spacer Onto Glass
      G02859656Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Cut off the old adhesive around the spacer installation area.
      NOTE: Be careful not to damage the body.
    3. Clean the installation area.
    4. Install a new spacer No. 1 onto the glass.
  12. INSTALL BACK WINDOW GLASS SPACER NO. 2 
  13. INSTALL BACK WINDOW MOLDING OUTSIDE 
    1. Install a new back window molding outside as shown in the illustration.
      Fig 5: Installing New Back Window Molding Outside
      G02859657Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      a: 2 mm (0.08 in.) 

  14. INSTALL BACK DOOR GLASS 
    1. Clean and shape the contact surface of the back door.
      1. Using a knife, cut away any rough adhesive on the contact surface of the body to shape the surface.
        NOTE: Leave as much of the adhesive on the back door as possible.
      2. Clean the cutting surface of the adhesive with a piece of shop rag saturated with cleaner.
      NOTE: Even if all the adhesive has been removed, clean the back door.
      Fig 6: Identifying Adhesive On Contact Surface Of Body
      G02859658Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Position glass.
      1. Using the suction rubber, place the glass in the correct position.
      2. Check that all contacting parts of the glass rim are perfectly even.
      3. Place reference marks between the glass and back door.
        Fig 7: Placing Reference Marks Between Glass And Back Door.
        G02859659Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      4. Remove the glass.
    3. Coat the contact surface of the back door with Primer M.
      1. Using a brush, coat the exposed part of back door on the vehicle side Primer M.
        Fig 8: Coating Contact Surface Of Back Door With Primer M
        G02859660Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Dry the primer coating dry for 3 minutes or more.
      • Do not apply Primer M onto the adhesive.
      • Do not keep any of the opened Primer M for later use.
    4. Using a brush or sponge, coat the edge of the glass and the contact surface with Primer G.
      NOTE: If the area other than the specified is coated by accident, wipe off the primer with a clean shop rag before it dries
      NOTE:
      • Dry the primer coating for 3 minutes or more.
      • Do not keep any of the opened Primer G for later use.
    5. Apply adhesive.
      Fig 9: Identifying Areas For Adhesive Application
      G02859661Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Cut off the tip of the cartridge nozzle, as shown in Fig 9.

        Part No. 08550-00801 or equivalent 

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

        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 9.

        a: 12 mm (047 in.) 

        b: 8 mm (0.31 in.) 

      NOTE:
      • Dry 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.
    6. Install the glass.
      1. Using a suction rubber, position the glass so that the reference marks are lined up, and press it in gently along the rim.
        Fig 10: Installing Back Door Glass At Correct Position
        G02859662Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        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.
        Fig 11: Removing Excess Adhesive Using Scraper
        G02859663Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      4. Using a scraper, remove any excess or protruding adhesive.
        Fig 12: Identifying Molding Attachment To Body Panel
        G02859664Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        NOTE: Confirm that the molding is attached to the body panel as shown in Fig 12.
        CAUTION: Take care not to drive the vehicle during the time described in INSTALLATION OF BACK DOOR GLASS SPECIFICATIONS  .
        INSTALLATION OF BACK DOOR GLASS SPECIFICATIONS

        Temperature Minimum Time Prior To Driving The Vehicle
        35° C(95° F) 1.5 Hours
        20° C(68° F) 5 Hours
        5° C(41° F) 24 Hours
      5. Hold the glass in place securely with a protective tape or equivalent until the adhesive hardness.
        Fig 13: Holding Glass In Place Securely With Protective Tape
        G02859665Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. WATER-LEAK CHECK AND REPAIR 
    1. Conduct a leak test after adhesive has completely hardened.
    2. Seal any leak with sealant.
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