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Back Door Glass: Installation

  1. CLEAN BACK DOOR GLASS 
    1. Using a scraper, remove the clips, dam and adhesive sticking to the back door glass.
      2. Fig 1: Cleaning Outer Circumference Of Back Door Glass
      G04833882Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Clean the outer edge of the back door glass with a non-residue solvent.
      NOTE:
      • Do not touch the back door glass surface after cleaning it.
      • Even if using a new back door glass, clean the back door glass with a non-residue solvent.

      HINT:

      Since the pin is for positioning the glass, there is no need to replace it with a new one when reusing the glass, even if damaged.

  2. CLEAN VEHICLE BODY 
    1. 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: Do not damage the vehicle body.

        HINT:

        Leave as much adhesive on the vehicle body as possible.

        Fig 2: Identifying Adhesive On Vehicle Body Contact Surface
        G04833862Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Clean the contact surface of the vehicle body with a shop rag or piece of cloth saturated with cleaner.

        HINT:

        Clean the vehicle body even if all the adhesive has been removed.

  3. INSTALL BACK WINDOW GLASS CLIP LH 
    1. Apply Primer G to the installation part of the back window glass clip.

      HINT:

      If primer is applied to an area that is not specified, wipe off the primer with a non-residue solvent before it dries.

      Fig 3: Applying Primer G To Installation Part Of Back Window Glass Clip
      G05403092Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the new clip onto the glass, as shown in the illustration.
      NOTE:
      • Allow the primer to dry for 3 minutes or more.
      • Throw away any leftover primer.
      • Do not apply too much primer.
  4. INSTALL BACK WINDOW GLASS CLIP RH 
    1. Apply Primer G to the installation part of the back window glass clip.

      HINT:

      If primer is applied to an area that is not specified, wipe off the primer with a non-residue solvent before it dries.

    2. Install the new clip onto the glass, as shown in the illustration.
      NOTE:
      • Allow the primer to dry for 3 minutes or more.
      • Throw away any leftover primer.
      • Do not apply too much primer.
        • Fig 4: Applying Primer G To Installation Part Of Back Door Glass Adhesive Dam
        G05403093Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL BACK WINDOW GLASS ADHESIVE DAM KIT 
    1. Apply Primer G to the installation part of the back door glass adhesive dam.
      NOTE:
      • Allow the primer to dry for 3 minutes or more.
      • Throw away any leftover primer.
      • Do not apply too much primer.

      HINT:

      If primer is applied to an area that is not specified, wipe off the primer with a non-residue solvent before it dries.

    2. Install 2 new back door glass adhesive dams, as shown in the illustration.
      Fig 5: Installing Back Door Glass Adhesive Dams
      G05403094Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Specification 

      AREA SPECIFICATIONS

      Area Measurement
      a 7.4 mm (0.291 in.)
      b 6.9 mm (0.273 in.)
  6. INSTALL BACK DOOR WINDOW MOULDING 
    1. Apply Primer G to the installation part of the back door window moulding.
      NOTE:
      • Allow the primer to dry for 3 minutes or more.
      • Throw away any leftover primer.
      • Do not apply too much primer.

      HINT:

      If an area other than that specified is coated by accident, wipe off the primer with a clean piece of cloth before it dries.

    2. Install a new back door window moulding, as shown in the illustration.
      Fig 6: Installing Back Door Window Moulding
      G05403095Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Specification 

      AREA SPECIFICATIONS

      Area Measurement
      a 3.5 mm (0.138 in.)
  7. INSTALL BACK DOOR GLASS 
    1. Position the back door glass.
      1. Using suction cups, place the back door glass in the correct position.
      2. Check that the whole contact surface of the back door glass rim is perfectly even.
      3. Place matchmarks on the back door glass and vehicle body.
        NOTE: Check that the stoppers are attached to the vehicle body correctly.

        HINT:

        When reusing the back door glass, check and correct the matchmark positions.

        Fig 7: Identifying Matchmarks On Back Door Glass And Vehicle Body
        G05403089Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      4. Using suction cups, remove the back door glass.
    2. Using a brush, apply Primer M to the exposed part of the vehicle body.
      NOTE:
      • Allow the primer 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 8: Applying Primer M To Exposed Part Of Vehicle Body
        G04833927Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a brush or sponge, apply Primer G to the edge of the back door glass and contact surface.
      Fig 9: Applying Primer G To Edge Of Back Door Glass And Contact Surface
      G05403098Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Allow the primer to dry for 3 minutes or more.
      • Throw away any leftover Primer G.
      • Do not apply too much Primer G.

      HINT:

      If Primer G is applied to any areas other than those specified, wipe off the primer with a clean shop rag or piece of cloth before it dries.

      Specification 

      AREA SPECIFICATIONS

      Area Measurement
      a 14.0 mm (0.551 in.)
      b 6.9 mm (0.272 in.)
      c 14.0 mm (0.551 in.)
      d 14.0 mm (0.551 in.)
      e 20.3 mm (0.799 in.)
      f 14.0 mm (0.551 in.)
    4. Apply adhesive.

      Adhesive: Toyota Genuine Windshield Glass Adhesive or equivalent 

      1. Cut off the tip of the cartridge nozzle, as shown in the illustration.
        Fig 10: Cutting Off Tip Of Cartridge Nozzle
        G04833929Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        HINT:

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

        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
      2. Load the sealer gun with a cartridge.
      3. Apply adhesive to the back door glass, as shown in the illustration.
        Fig 11: Applying Adhesive To Back Door Glass
        G05403100Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Specification 

        AREA SPECIFICATIONS

        Area Measurement
        a 12.0 mm (0.472 in.)
        b 8.0 mm (0.315 in.)
        c 10.9 mm (0.429 in.)
        d 14.0 mm (0.551 in.)
        e 24.3 mm (0.957 in.)
        f 14.0 mm (0.551 in.)
    5. Install the back door glass onto the vehicle body.
      1. Using suction cups, position the back door glass so that the matchmarks are aligned. Press it in gently along the rim.
        NOTE:
        • Allow the primer to dry for 3 minutes or more.
        • Check that the stoppers are attached to the vehicle body correctly.
        • Check that the vehicle body and back door glass have a small gap between them.
          • Fig 12: Identifying Matchmarks
          G05403089Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Gently press the front surface of the back door glass to ensure that the back door glass is securely fitted to the vehicle body.
      3. Using a scraper, remove any excessive or protruding adhesive.

        HINT:

        Apply adhesive onto the back door glass rim.

        Fig 13: Removing Excessive Or Protruding Adhesive
        G04833932Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        NOTE: Do not drive the vehicle within the time limits described in the table below.

        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
  8. CHECK FOR LEAKAGE AND REPAIR 
    1. After the adhesive has hardened, apply water from the outside of the vehicle. Check that no water leaks into the cabin.
    2. If water leaks into the cabin, allow the water to dry and add adhesive.
    3. Remove the protective tape.
  9. INSTALL REAR SPOILER SUB-ASSEMBLY  (See INSTALLATION )
  10. INSTALL REAR WIPER MOTOR GROMMET  (See INSTALLATION )
  11. INSTALL REAR WIPER MOTOR  (See INSTALLATION )
  12. INSTALL REAR WIPER ARM AND BLADE ASSEMBLY  (See INSTALLATION )
  13. INSTALL BACK DOOR TRIM BOARD ASSEMBLY  (See REASSEMBLY )
  14. INSTALL BACK DOOR INSIDE HANDLE  (See REASSEMBLY )
  15. INSTALL BACK DOOR SIDE GARNISH LH  (See REASSEMBLY )
  16. INSTALL BACK DOOR SIDE GARNISH RH 

    HINT:

    Use the same procedure as for the LH side.

  17. INSTALL BACK DOOR TRIM UPPER PANEL ASSEMBLY  (See REASSEMBLY )
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