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Back Window Glass: Replacement

HINT:

Installation is according to the reverse order of the removal.

  1. REMOVE REAR SEAT CUSHION ASSY (See  OVERHAUL  ) 
  2. REMOVE REAR SEAT BACK ASSY (See  OVERHAUL  ) 
  3. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP RH 
  4. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH 
  5. REMOVE ROOF SIDE GARNISH INNER RH (See  REPLACEMENT  ) 
  6. REMOVE ROOF SIDE GARNISH INNER LH (See  REPLACEMENT  ) 
  7. REMOVE ASSIST GRIP SUB-ASSY (See  REPLACEMENT  ) 
  8. REMOVE ROOF HEADLINING ASSY (See  REPLACEMENT  ) 
  9. REMOVE CENTER STOP LAMP ASSY (See  LICENSE PLATE LAMP LENS  ) 
  10. REMOVE PACKAGE TRAY TRIM PANEL ASSY (W/O SUN SHADE) (See  REPLACEMENT  ) 
  11. REMOVE PACKAGE TRAY TRIM PANEL ASSY (W/ SUN SHADE) (See  REPLACEMENT  ) 
  12. REMOVE PACKAGE TRAY TRIM PANEL ASSY NO.2 (W/ SUN SHADE) 
    1. Remove the package tray trim panel assembly No.2 as shown in the illustration.
      Fig 1: Locating Package Tray Trim Panel Assembly
      G02936245Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE BACK WINDOW MOULDING OUTSIDE UPPER 
    Fig 2: Cutting Off Moulding Using Knife
    G02936246Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a knife, cut off the moulding as shown in the illustration.
      NOTE: Do not damage the body with the knife.
    2. Remove the remaining moulding.

      HINT:

      When removing, make a cut partly, pull and remove it by hand.

  14. REMOVE BACK WINDOW GLASS 

    HINT:

    There is a case where a 1 -piece type and a 2-piece type of stoppers are installed in a vehicle type.

    1. Push a piano wire through between the body and glass from the interior.
    2. Apply protective tape to the outer surface to keep the surface from being scratched.
    3. Tie both wire ends to wooden blocks or similar objects.
      Fig 3: Locating Buck Window Glass
      G02936247Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • 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.
      Fig 4: Cutting Adhesive By Pulling Piano Wire
      G02936248Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Cut the adhesive by pulling the piano wire around it.
    5. Using a suction rubber, remove the glass.
    NOTE: Leave as much adhesive on the body as possible when cutting off the glass.
  15. REMOVE BACK WINDOW GLASS 
    1. Using a scraper, remove the damaged spacers and clips, dam and adhesive sticking to the glass.
    2. Clean the outer circumference of the glass with white gasoline.
    NOTE:
    • Do not touch the glass after cleaning it.
    • Be careful not to damage the body.
    Fig 5: Cleaning Back Window Glass
    G02936249Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSTALL BACK WINDOW GLASS STOPPER NO.1 
    1. Install the 2 new windshield glass stoppers No.1 to the body.
  17. 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 the 2 new windshield glass stoppers No.2 onto the glass as shown in the illustration. 
    1. A: 11.2 mm (0.441 in.) 
    2. B: 40 mm (1.57 in.) 
  18. INSTALL BACK WINDOW MOULDING OUTSIDE UPPER
    1. Install a new windshield moulding 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.

    HINT:

    Follow the manufacture's instruction about the minimum drying time, driving endurance time and etc. for the adhesive.

    Fig 6: Installing Back Window Glass Stopper No. 2
    G02936250Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. INSTALL BACK WINDOW GLASS 
    1. Clean and shape the contact surface of the vehicles body
      1. Using a knife, cut away any rough areas on the body.

        HINT:

        Leave as much adhesive on the body as possible.

      2. Clean the cut surface of the adhesive with a piece of shop rag saturated in cleaner.
      Fig 7: Locating Stoppers
      G02936251Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Position the glass.
      1. Using a suction rubber, place the glass in the correct position.
      2. Check that all the contacting parts of the glass rim are perfectly even.
      3. Place reference marks between the glass and body.
        NOTE: Check that the stoppers are attached to the body correctly.

        HINT:

        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 Primer M to the exposed part of the contact surface 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. Coat the contact surface of the glass with Primer G.
      1. Using a brush or sponge, coat the edge of the glass and the contact surface with Primer G.
        NOTE:
        • Dry the primer coating for 3 minutes or more.
        • Do not apply too much primer.
    6. Apply adhesive.
      1. Cut off the tip of the cartridge nozzle as shown in the illustration.
        1. Part No. 08850-00801 or equivalent 

        HINT:

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

        Fig 8: Applying Adhesive
        G02936252Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEMPERATURE OF TIME DESCRIBED

        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 the illustration.
      1. a: 8 mm (0.31 in.) 
      2. b: 12 mm (0.47 in.) 
      3. 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 alined, 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: Take care not to drive the vehicle during the time described in the table below.
    TEMPERATURE AND TIME DESCRIBED

    Temperature Tackfree time
    35°C (95°F) 1.5 hours
    20°C (68°F) 5 hours
    5°C (41°F) 24 hours

    HINT:

    Apply adhesive on the glass rim.

  20. 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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