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 ).

w/ Rear wiper:
REMOVE REAR WIPER ARM ASSY (See REAR WIPER MOTOR ASSY )
REMOVE BACK DOOR SIDE GARNISH (See BACK DOOR GARNISH )
1. Remove the back door trim board (lower).
2. Remove the back door trim board (upper).
3. Remove the back door trim panel upper.
4. Remove the back door side garnish LH and RH.
w/ Rear wiper:
REMOVE REAR WIPER MOTOR ASSY (See REAR WIPER MOTOR ASSY )
REMOVE REAR SPOILER SUB-ASSY (See REAR SPOILER SUB-ASSY )
REMOVE BACK DOOR GLASS
1. From the interior, insert piano wires between the vehicle body and glass, as shown in Fig 1 .
2. Tie objects that can serve as handles (for example, wooden blocks) to all wire ends.
  
  Fig 1: Inserting Piano Wires Between Vehicle Body And Glass
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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.
3. Cut through the adhesive by pulling the piano wire around the glass.
4. Using a suction cup, remove the glass.
NOTE: Leave as much adhesive on the vehicle body as possible when removing the glass.

Fig 2: Applying Protective Tape To Outer Surface Of Vehicle Body
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CLEAN BACK DOOR GLASS
1. Using a scraper, remove the spacer, dam, moulding and adhesive sticking to 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 the glass with white gasoline.
Fig 3: Cleaning Back Door 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 4 .
    HINT:
    
    Leave as much adhesive on the vehicle body as possible.
    
    Fig 4: Cleaning Vehicle Body
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    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 5: Installing Back Window Glass Spacer
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BACK WINDOW GLASS SPACER
1. Apply Primer G to the glass where the spacers will be installed.
  NOTE:
  - Allow the primer to coating 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 5 .
INSTALL BACK DOOR GLASS ADHESIVE DAM
1. Apply Primer G to the glass where the adhesive dam will be installed.
  NOTE:
  - Allow the primer to dry for 3 minutes or more.
  - Throw away any leftover Primer G.
  - Do not apply too much Primer G.
2. 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: Removing Peeling Paper From Adhesive Part Of Dam
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL BACK WINDOW MOULDING OUTSIDE

Using a brush or sponge, coat the edge of the glass and the contact surface with Primer G.

Fig 7: Coating Edge Of Glass And Contact Surface

Courtesy 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.

Specification:

AREA MEASUREMENT SPECIFICATIONS

Area	Measurement
a	10.0 mm (0.394 in.)

Install the moulding.

Fig 8: Installing Moulding

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Specification:

AREA MEASUREMENT SPECIFICATIONS

Area	Measurement
a	4.5 mm (0.177 in.)
b	1.5 mm (0.059 in.)
c	24.2 mm (0.953 in.)

INSTALL BACK DOOR GLASS

Using a brush, coat the exposed part of the vehicle body with Primer M.

Fig 9: Coating Exposed Part Of Vehicle Body With Primer M
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
NOTE:
- Allow the primer to dry for 3 minutes or more.
- Do not coat the adhesive with Primer M.
- Throw away any leftover Primer M.
- Do not apply too much Primer M.
Using a brush or sponge, coat the edge of the glass and the contact surface with Primer G.

Fig 10: Coating Edge Of Glass And Contact Surface With Primer G
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

If Primer G is applied to an area other than that which is specified, wipe off the primer with cloth before it dries.
NOTE:
- Allow the primer to dry for 3 minutes or more.
- Throw away any leftover Primer G.
- Do not apply too much Primer G.

Apply adhesive.

Adhesive: Part No. 08850-00801 or equivalent

Fig 11: Applying Adhesive

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

HINT:

After cutting off the tip, use all adhesive within the time written 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

Load the sealer gun with the cartridge.
Coat the glass with adhesive, as shown in Fig 11 .

Specification:

AREA MEASUREMENT SPECIFICATIONS

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

Install the back door glass to the vehicle body.

Hold the back door glass in place securely with protective tape or equivalent until the adhesive hardens.
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.
Lightly press the front surface of the glass to ensure that the glass is securely fit to the vehicle body.
Using a scraper, remove any excess or protruding adhesive.

HINT:

Apply adhesive onto the glass rim.

NOTE: Do not drive the vehicle for the amount of time written 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

CHECK FOR LEAKS AND REPAIR
1. Conduct a leak test after the adhesive has completely hardened.
2. Seal any leaks with auto glass sealer.
Fig 12: Removing Any Excess Or Protruding Adhesive
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002