Back Window 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 table (see SPECIFIED TORQUE FOR STANDARD BOLTS ).

REMOVE ROOF SIDE GARNISH INNER RH (See REPLACEMENT )
REMOVE ROOF SIDE GARNISH INNER LH (See REPLACEMENT )
REMOVE ROOF HEADLINING ASSY REAR (See REPLACEMENT )
REMOVE BACK WINDOW OUTSIDE MOLDING
1. Using a knife, cut through the molding as shown in Fig 1.
  NOTE: Be careful not to damage the vehicle body with the knife.
2. Remove the remaining molding.
HINT:

Make a partial cut in the molding. Then pull and remove it by hand.

Fig 1: Removing Back Window Outside Molding
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BACK WINDOW GLASS
1. Remove the 2 nuts.
  
  Fig 2: Removing Back Window Glass Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. From the interior, insert a piano wire between the vehicle body and glass as shown in Fig 3.
3. Tie objects that can serve as handles (for example, wooden blocks) to both wire ends.
  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.
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 3: Inserting Piano Wire Between Vehicle Body & Glass
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BACK WINDOW PACKING
1. Remove the back window packing.
  
  Fig 4: Removing Back Window Packing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CLEAN BACK WINDOW GLASS
1. Using a scraper, remove the damaged dams and adhesive sticking to the glass.
2. Clean the outer edges of the glass with white gasoline.
  NOTE:
  - Do not touch the glass surface after cleaning it.
  - Even if using new glass, clean it with white gasoline.
  Fig 5: Cleaning Back Window Glass
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL BACK WINDOW GLASS ADHESIVE DAM

Apply Primer G to the installation part of the glass adhesive dam.
NOTE:
- Allow the Primer G to dry for 3 minutes or more.
- Throw away any leftover Primer G.
- Do not apply too much Primer G.

Remove the peeling paper from the adhesive part of the dam. Install the dam (adhesive side) to the glass (Primer G area) as shown in Fig 6.

Fig 6: Installing Back Window Glass Adhesive Dam

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Specification:

BACK WINDOW GLASS ADHESIVE DAM

Area	Measurement
a	0.7 mm (0.028 in.)

INSTALL BACK WINDOW OUTSIDE MOLDING
1. Using a brush or sponge, apply Primer G to the glass where the molding will be installed.
  NOTE:
  - Allow the Primer G to dry for 3 minutes or more.
  - Throw away any leftover Primer G.
  - Do not apply too much Primer G.
2. Install the back window outside molding.
INSTALL BACK WINDOW PACKING
1. Using a brush, apply Primer M to the exposed part of the vehicle body.
  NOTE:
  - Allow the Primer M to dry for 3 minutes or more.
  - Throw away any leftover Primer M.
2. Install the back window packing
  
  Fig 7: Installing Back Window Packing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL BACK WINDOW GLASS

Clean and shape the contact surface of the vehicle body.
1. On the contact surface of the vehicle body, use a knife to cut away excess adhesive as shown in Fig 8.
  HINT:
  
  Leave as much adhesive on the vehicle body as possible.
  
  NOTE: Be careful not to damage the vehicle body.
2. Clean the contact surface of the vehicle body with cleaner.
  HINT:
  
  Even if all the adhesive has been removed, clean the vehicle body.
  
  Fig 8: Cutting Excess Adhesive
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Position the glass.
1. Using a suction cup, place the glass in the correct position.
2. Check that the entire contact surface of the glass rim is perfectly even.
3. Place matchmarks over the glass and vehicle body on the locations indicated in Fig 9.
  HINT:
  - Placing matchmarks is only necessary if the glass being installed is new. If it is reused glass, matchmarks should already be present.
  - When reusing the glass, check and correct the match-mark positions.
4. Using a suction cup, remove the glass.
  
  Fig 9: Positioning Glass
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using a brush, apply Primer M to the exposed part of the vehicle body.
NOTE:
- Allow the Primer M 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 10: Applying Primer M To Exposed Part Of Vehicle Body Using Brush
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using a brush or sponge, apply Primer G to the contact surface of the glass.
HINT:

If Primer G is applied to an area that is not specified, apply white gasoline to a clean cloth and wipe off the excess primer.
NOTE:
- Allow the Primer G to dry for 3 minutes or more.
- Throw away any leftover Primer G.
- Do not apply too much Primer G.
Fig 11: Applying Primer G To Contact Surface Of Glass
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Apply adhesive to the glass.

Adhesive: Part No. 08850-00801 or equivalent

Cut off the tip of the cartridge nozzle as shown in Fig 12.

HINT:

After cutting off the tip, use all adhesive within the time written in TEMPERATURE TABLE .

Usage time frame:

USAGE TIME FRAME

Temperature	Usage Timeframe
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.

Apply adhesive to the glass as shown in Fig 12.

Specification:

MEASUREMENT TABLE

Area	Measurement
a	12.0 mm (0.472 in.)
b	8.0 mm (0.315 in.)
c	14.5 mm (0.571 in.)

Fig 12: Applying Adhesive To Glass

Install the glass to the vehicle body.

Using a suction cup, position the glass so that the matchmarks are aligned. Press it in gently along the rim.

Fig 13: Positioning Glass Using Suction Cup
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Lightly press the front surface of the glass to ensure that it is securely fit to the vehicle body.
NOTE: Check that the vehicle body and glass have a small gap between them.
Hold the glass in place securely with protective tape or equivalent until the adhesive hardens.
Using a scraper, remove any excess or protruding adhesive.

Fig 14: Removing Excess Or Protruding Adhesive Using Scraper
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

Apply adhesive on the glass rim.

NOTE: Do not drive the vehicle for the amount of time written in TEMPERATURE TABLE .

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

Fig 15: Applying Adhesive On Glass Rim

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