Back Door Glass: Replacement

HINT:

The installation procedures are the removal procedures in reverse order. However, only installation procedures requiring additional information are included.
A bolt without a torque specification is shown in the standard bolt chart (see SPECIFIED TORQUE FOR STANDARD BOLTS ).

REMOVE ASSIST STRAP HOLE COVER (See OVERHAUL )
REMOVE ASSIST STRAP ASSY RH (See OVERHAUL )
REMOVE BACK DOOR TRIM PANEL ASSY (See OVERHAUL )
REMOVE BACK WINDOW PANEL TRIM UPPER (See OVERHAUL )
REMOVE BACK DOOR TRIM COVER RH (See OVERHAUL )
REMOVE BACK DOOR TRIM COVER LH (See OVERHAUL )
REMOVE REAR WIPER ARM ASSY (See REAR WIPER MOTOR ASSY )
REMOVE REAR SPOILER (W/ REAR SPOILER) (See REAR SPOILER )
REMOVE BACK DOOR GLASS
1. Disconnect the connector.
2. From the interior, insert piano wires between the vehicle body and glass, as shown in the illustration.
3. Tie objects that can serve as handles (for example, wooden blocks) to all wire ends.
  
  Fig 1: Inserting Piano Wires Between Vehicle Body And Glass
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  Apply protective tape to the outer surface of the vehicle body to prevent its surface from being scratched.
  NOTE:
  - When separating the glass from the vehicle, be careful not to damage the vehicle's paint or interior/exterior ornaments.
  - To prevent the safety pad from being scratched when removing the glass, place a plastic sheet between the piano wire and safety pad.
4. Cut through the adhesive by pulling the piano wire around the glass.
5. Using a suction cup, remove the glass.
NOTE: Leave as much adhesive on the vehicle body as possible when removing the glass.

Fig 2: Applying Protective Tape To Outer Surface Of Vehicle Body
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CLEAN BACK DOOR GLASS
1. Using a scraper, remove the damaged spacers, molding and adhesive sticking to the glass.
2. Clean the outer circumference of the glass with white gasoline.
NOTE:
- Do not touch the glass surface after cleaning it.
- Even if using new glass, clean the glass with white gasoline.
  
  Fig 3: Cleaning Back Door Glass
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BACK DOOR GLASS SPACER NO. 1
1. Coat the installation part of the spacers with Primer G.
  NOTE:
  - Allow the primer coating to dry for 3 minutes or more.
  - Throw away any leftover Primer G.
  - Do not apply too much Primer G.
2. Install 2 new spacers onto the glass, as shown in the illustration.
INSTALL BACK WINDOW GLASS SPACER NO. 2

Fig 4: Installing Back Door Glass Spacer No. 1
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BACK WINDOW MOLDING OUTSIDE
1. Coat the installation part of the back window molding outside with Primer G.
  NOTE:
  - Allow the primer coating to dry for 3 minutes or more.
  - Throw away any leftover Primer G.
  - Do not apply too much Primer G.
2. Install a new back window molding outside, as shown in the illustration.
Specification:
BACK WINDOW MOLDING OUTSIDE SPECIFICATION

Area Measurement

a 2 mm (0.08 in.)

Fig 5: Installing Back Window Molding Outside
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL BACK DOOR GLASS

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: Be careful not to damage the vehicle body.
  
  HINT:
  
  Leave as much of the adhesive on vehicle body as possible.
2. Clean the contact surface of the vehicle body with a piece of shop rag saturated with cleaner.
HINT:

Even if all the adhesive has been removed, clean the vehicle body.

Fig 6: Cutting Away Any Rough Adhesive On Contact Surface Of Vehicle Body
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using a brush, coat the exposed part of the vehicle body with Primer M.
NOTE:
- Allow the primer coating to dry for 3 minutes or more.
- Do not coat the adhesive with Primer M.
- Throw away any leftover Primer M.
- Do not apply too much Primer M.
Using a brush or sponge, coat the edge of the glass and the contact surface with Primer G.
HINT:

If the area other than that specified is coated by accident, wipe off the primer with a clean shop rag before it dries
NOTE:
- Allow the primer coating to dry for 3 minutes or more.
- Throw away any leftover Primer G.
- Do not apply too much Primer G.
Fig 7: Coating Exposed Part Of Vehicle Body With Primer M
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Apply adhesive.

Adhesive: Part No. 08850-00801 or equivalent

Fig 8: Applying Adhesive

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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 described in the table below.

Usage of time frame:

USAGE OF 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

Load the sealer gun with the cartridge.
Coat the glass with adhesive, as shown in the illustration.

Specification:

ADHESIVE SPECIFICATION

Area	Measurement
a	12 mm (0.47 in.)
b	8 mm (0.31 in.)
c	12 mm (0.47 in.)

Install the back window glass to the vehicle body.

Hold the back window glass in place securely with protective tape or equivalent until the adhesive hardens.
NOTE:
- Allow the primer coating to dry for 3 minutes or more.
- Check that the spacers are attached to the vehicle body correctly.
- Check that the vehicle body and glass have a small gap between them.

Lightly press the front surface of the glass to ensure that the glass is securely fit to the vehicle body.

NOTE: Do not drive the vehicle for the amount of time described in the table below.

Minimum time:

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

Hold the glass in place securely with a protective tape or equivalent until the adhesive hardens.

Fig 9: Holding Glass In Place Securely With Protective Tape

CHECK FOR LEAKS AND REPAIR
1. Conduct a leak test after the adhesive has completely hardened.
2. Seal any leaks with auto glass sealer.