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 BACK DOOR TRIM BOARD ASSY (See OVERHAUL )
1. Remove the back door garnish center.
2. Remove the back door side garnish LH and RH.
3. Remove the back door trim board.
REMOVE BACK DOOR GLASS
1. Apply protective tape to the outer surface of the vehicle body to prevent scratches.
2. From the interior, insert piano wires between the vehicle body and glass as shown in Fig 1 .
3. Tie objects that can serve as handles (for example, wooden blocks) to all wire ends.
  NOTE: When separating the back door 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.
  NOTE: Leave as much adhesive on the vehicle body as possible when cutting through the adhesive.
5. Using a suction cup, remove the glass.
  
  Fig 1: Removing Back Door Glass
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CLEAN BACK DOOR GLASS
1. Using a scraper, remove the spacers, moulding and adhesive from the glass.
2. Clean the outer edge 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 2: Removing Spacers, Moulding And Adhesive From The Glass
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CLEAN VEHICLE BODY
1. 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 3 .
    HINT:
    
    Leave as much adhesive on the vehicle body as possible.
    
    NOTE: Be careful not to damage the vehicle body.
    
    Fig 3: Cleaning And Shape The Contact Surface Of The Vehicle Body
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Clean the contact surface of the vehicle body with cleaner.
  HINT:
  
  Even if all the adhesive has been removed, clean the vehicle body.
INSTALL BACK WINDOW GLASS SPACER
1. Apply Primer G to the glass where the spacers will be installed.
  HINT:
  
  If Primer G is applied to an area 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.
2. Install 2 new spacers onto the glass as shown in Fig 4 .
  
  Fig 4: Installing Back Window Glass Spacer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL BACK WINDOW GLASS ADHESIVE DAM KIT

Apply Primer G to the glass where the adhesive dam will be installed.

SPECIFICATION:

AREA MEASUREMENT SPECIFICATIONS

Area	Measurement
a	14.0 mm (0.551 in.)

HINT:

If Primer G is applied to an area 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 5: Installing Back Window Glass Adhesive Dam Kit

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Install the adhesive dam as shown in Fig 6 .

Fig 6: Installing The Adhesive Dam

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

SPECIFICATION:

AREA MEASUREMENT SPECIFICATIONS

Area	Measurement
a	1,090.0 mm (42.913 in.)

INSTALL BACK WINDOW GLASS ADHESIVE DAM NO. 2

Cut the adhesive dam as shown in Fig 7 .

Install the adhesive dam as shown in Fig 7 .

Fig 7: Installing Back Window Glass Adhesive Dam No

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

SPECIFICATION:

AREA MEASUREMENT SPECIFICATIONS

Area	Measurement
a	1,320.0 mm (51.968 in.)
b	1,258.0 mm (49.527 in.)

INSTALL BACK WINDOW OUTSIDE MOULDING

Cut the moulding LH and RH as shown in Fig 8 .

Install the moulding LH and RH as shown in Fig 8 .

Fig 8: Installing Moulding LH And RH

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

SPECIFICATION:

AREA MEASUREMENT SPECIFICATIONS

Area	Measurement
a	853.0 mm (33.583 in.)
b	823.0 mm (32.402 in.)
c	2.3 mm (0.091 in.)

INSTALL BACK DOOR GLASS

Using a brush or sponge, 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 9: Applying Primer M To The Exposed Part Of The Vehicle Body
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using a brush or sponge, apply Primer G to the contact surface of the glass.

Fig 10: Applying Primer G To The Contact Surface Of The Glass

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

SPECIFICATION:

AREA MEASUREMENT SPECIFICATIONS

Area	Measurement
a	85.6 mm (3.370 in.)

HINT:

If Primer G is applied to an area 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.

Apply adhesive to the back door glass.

Adhesive: Part No. 08850-00801 or equivalent

Cut off the tip of cartridge nozzle as shown in Fig 11 .

HINT:

After cutting off the tip, use all adhesive within the time written in the table shown in TEMPERATURE SPECIFICATION .

USAGE TIME FRAME:

TEMPERATURE SPECIFICATIONS

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.
Apply adhesive to the glass as shown in Fig 11 .

Fig 11: Applying Adhesive To The Glass
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

SPECIFICATION:

AREA MEASUREMENT SPECIFICATIONS

Area	Measurement
a	12.0 mm (0.472 in.)
b	8.0 mm (0.315 in.)
c	85.6 mm (3.370 in.)

Install the back door glass to the vehicle body.

Lightly press the front surface of the glass to ensure that it is securely fit to the vehicle body.
NOTE:
- Check that the spacers are attached to the vehicle body correctly.
- 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.

NOTE: Do not drive the vehicle for the amount of time written in the table shown in TEMPERATURE SPECIFICATION .

MINIMUM TIME:

TEMPERATURE SPECIFICATIONS

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

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