Back Door Glass: Replacement

HINT: The installation procedures are the removal procedures in reverse order. However, only installation procedures requiring additional information are included.

REMOVE BACK DOOR GLASS
1. From the interior, insert piano wines between the vehicle body and glass, as shown in the illustration.
2. Tie objects that can serve as handles (for example, wooden blocks) to all wire ends.
  
  Fig 1: Inserting Piano Wines Between Vehicle Body & Glass
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT: Apply protective tape to the outer surface of the vehicle to prevent its surface from being scratched.
  
  NOTE: When separating the glass from the vehicle, take care not to damage the paint and interior/exterior ornaments.
3. Cut through the adhesive by pulling the piano wire around the glass.
  NOTE: If the back door glass will be reused, be careful not to damage the clip attached to the glass when you cut off the adhesive.
  
  Fig 2: Applying Protective Tape To Outer Surface
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a suction cup, remove the glass.
  NOTE: Leave as much adhesive on the vehicle body as possible when removing the glass.
CLEAN BACK DOOR GLASS
1. Clean the outer edges of the glass with white gasoline.
  NOTE:
  - Do not touch the glass surface after cleaning it.
  - Be careful not to damage the glass.
  - Even if using new glass, clean the glass with white gasoline.
    
    Fig 3: Cleaning Outer Edges Of Glass With White Gasoline
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL BACK WINDOW GLASS CLIP

Apply Primer G to the installation part of the clips.

Install new clips.

NOTE:

Allow the primer coating to dry for 3 minutes or more.
Throw away any leftover Primer G.
Do not apply too much primer.

Specification:

AREA AND MEASUREMENT SPECIFICATION

Area	Measurement
a	465.4 mm (18.323 in.)
b	44.8 mm (1.764 in.)

Fig 4: Applying Primer G To Installation Part Of Clips

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL BACK DOOR GLASS SPACER
1. Apply Primer G to the installation part of the spacers.
2. Install new spacers.
  NOTE:
  - Allow the primer coating to dry for 3 minutes or more.
  - Throw away any leftover Primer G.
  - Do not apply too much primer.
    
    Fig 5: Applying Primer G To Installation Part Of Spacers
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL BACK DOOR WINDOW MOLDING

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

Install new moldings applying double-sided tape, as shown in the illustration.

Fig 6: Installing New Moldings Applying Double-Sided Tape

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Specification:

AREA AND MEASUREMENT SPECIFICATION

Area	Measurement
a	4.7 mm (0.185 in.)
b	3.0 to 7.0 mm (0.118 to 0.276 in.)
c	5.0 to 7.0 mm (0.197 to 0.276 in.)

INSTALL BACK DOOR GLASS

Clean and shape the contact surface of the adhesive on the vehicle body.
1. Using a knife, cut away any excess or unneeded adhesive on the contact surface.
  HINT: Leave as much adhesive on the vehicle body as possible.
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 7: Cleaning & Shaping Contact Surface Of Adhesive On Vehicle Body
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using a brush, apply Primer M to the exposed part of the vehicle body.
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.
  
  Fig 8: Applying Primer M To Exposed Part Of Vehicle Body
  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 accidentally applied to another part of the vehicle, wipe off the primer with cleaner 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.

Fig 9: Applying Primer G To Contact Surface Of Glass

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Specification:

AREA AND MEASUREMENT SPECIFICATION

Area	Measurement
a	3.0 mm (0.118 in.)
b	10.7 mm (0.421 in.)
c	10.7 mm (0.421 in.)
d	5.8 mm (0.228 in.)

Apply adhesive.

Adhesive: Part No. 08850-00801 or equivalent

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 written in the table below.

Usage Time-frame:

TEMPERATURE AND USAGE TIME-FRAME SPECIFICATION

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 the illustration.

Fig 10: Applying Adhesive To Glass

Specification:

AREA AND MEASUREMENT SPECIFICATION

Area	Measurement
a	8.0 mm (0.315 in.)
b	12.0 mm (0.472 in.)
c	6.0 mm (0.236 in.)
d	10.7 mm (0.421 in.)
e	10.7 mm (0.421 in.)
f	8.8 mm (0.346 in.)

Install the glass to the vehicle body.

Hold the back window glass in place securely with tape or equivalent to the vehicle body until the adhesive has hardened.
NOTE:
- Allow the primer coating to dry for 3 minutes or more.
- Check that the clips are attached to the vehicle body correctly.
- Check the clearance between the vehicle body and glass.
Lightly press the front surface of the glass to ensure a close fit.

Using a scraper, remove any excess or protruding adhesive.

HINT: Apply adhesive onto the glass rim.

NOTE: Do not to drive the vehicle within the time written in the table below.

Minimum time:

TEMPERATURE AND MINIMUM TIME PRIOR TO DRIVING VEHICLE SPECIFICATION

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 11: Removing Excess Or Protruding Adhesive

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