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Back Window ASSY: Replacement

  1. REMOVE REAR SEAT BACK HINGE COVER (DOUBLE CAB)  (See OVERHAUL
  2. REMOVE REAR SEAT BACK ASSY LH (DOUBLE CAB)  (See OVERHAUL
  3. REMOVE REAR SEAT BACK ASSY RH (DOUBLE CAB)  (See OVERHAUL
  4. REMOVE REAR SEAT BACK HINGE SUB-ASSY LH (DOUBLE CAB)  (See OVERHAUL
  5. REMOVE REAR SEAT BACK HINGE SUB-ASSY RH (DOUBLE CAB)  (See OVERHAUL
  6. REMOVE FRONT DOOR SCUFF PLATE LH (EXCEPT DOUBLE CAB) 

    HINT:

  7. REMOVE FRONT DOOR SCUFF PLATE RH (EXCEPT DOUBLE CAB) 

    HINT:

    Follow the same procedures as for the front door scuff plate LH.

  8. REMOVE REAR DOOR SCUFF PLATE LH (EXCEPT REGULAR CAB) 

    HINT:

  9. REMOVE REAR DOOR SCUFF PLATE RH (EXCEPT REGULAR CAB) 

    HINT:

    Follow the same procedures as for the rear door scuff plate LH.

  10. REMOVE ROOF SIDE INNER GARNISH CAP LH (ACCESS CAB)  (See REPLACEMENT
  11. REMOVE ROOF SIDE INNER GARNISH CAP RH (ACCESS CAB) 

    HINT:

    Follow the same procedures as for the roof side inner garnish LH.

  12. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP LH (EXCEPT DOUBLE CAB) 

    HINT:

  13. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP RH (EXCEPT DOUBLE CAB) 

    HINT:

    Follow the same procedures as for the front door opening trim weatherstrip LH.

  14. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH (DOUBLE CAB)  (See REPLACEMENT
  15. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP RH (DOUBLE CAB) 

    HINT:

    Follow the same procedures as for the rear door opening trim weatherstrip LH.

  16. REMOVE BACK PANEL TRIM COVER (EXCEPT DOUBLE CAB) 

    HINT:

  17. REMOVE BACK PANEL TRIM COVER (REGULAR CAB (BENCH SEAT TYPE)  (See REPLACEMENT
  18. REMOVE BACK PANEL GARNISH UPPER (REGULAR CAB)  (See REPLACEMENT
  19. REMOVE JACK ASSY (REGULAR CAB (SEPARATE SEAT TYPE)  (See REPLACEMENT
  20. REMOVE BACK PANEL TRIM COVER (REGULAR CAB (SEPARATE SEAT TYPE)  (See REPLACEMENT
  21. REMOVE BACK PANEL TRIM (ACCESS CAB, REGULAR CAB (SEPARATE SEAT TYPE)  (See REPLACEMENT
  22. REMOVE LUGGAGE COMPARTMENT SIDE TRAY (DOUBLE CAB)  (See REPLACEMENT
  23. REMOVE REAR SEAT BACK HINGE SUB-ASSY CENTER (DOUBLE CAB)  (See OVERHAUL
  24. REMOVE LUGGAGE COMPARTMENT SIDE TRAY (DOUBLE CAB)  (See REPLACEMENT
  25. REMOVE QUARTER TRIM PANEL LOWER LH 

    HINT:

  26. REMOVE QUARTER TRIM PANEL LOWER RH 

    HINT:

    Follow the same procedures as for the quarter trim panel lower LH.

  27. REMOVE ROOF SIDE GARNISH INNER LH (ACCESS CAB)  (See REPLACEMENT
  28. REMOVE ROOF SIDE GARNISH INNER RH (ACCESS CAB) 

    HINT:

    Follow the same procedures as for the roof side garnish inner LH.

  29. REMOVE QUARTER INSIDE TRIM BOARD LH 

    HINT:

  30. REMOVE QUARTER INSIDE TRIM BOARD RH 

    HINT:

    Follow the same procedures as for the quarter inside trim board LH.

  31. REMOVE COAT HOOK 

    HINT:

  32. REMOVE BACK WINDOW ASSY 
    1. Remove the 2 nuts.
      Fig 1: Removing Back Window Assy Nuts
      G03089160Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Apply protective tape to the outer circumference of the back window, as shown in the illustration.
    3. From the interior, insert piano wires between the vehicle body and back window, as shown in the illustration.
    4. Tie objects that can serve as handles (for example, wooden blocks) to all wire ends.
      NOTE: When separating the back window from the vehicle, be careful not to damage the vehicle's paint or exterior/interior ornaments.
    5. Cut through the adhesive by pulling the piano wire around the back window.
      Fig 2: Applying Protective Tape To Outer Circumference Of Back Window
      G03089161Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Disengage the 2 clips.
    7. Using suction cups, remove the back window.
      NOTE: Leave as much adhesive on the vehicle body as possible when removing the back window.
      Fig 3: Removing Back Window Using Suction Cups
      G03089162Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. 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: Be careful not to damage the vehicle body.

        HINT:

        Leave as much adhesive on the vehicle body as possible.

        Fig 4: Cutting Away Rough Adhesive On Contact Surface Of Vehicle Body
        G03089163Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Clean the contact surface of the vehicle body with a shop rag saturated with cleaner.

        HINT:

        Even if all the adhesive has been removed, clean the vehicle body.

  34. INSTALL BACK WINDOW ASSY 
    1. Position the windshield glass.
      1. Using suction cups, place the back window in the correct position.
      2. Check that the whole contact surface of the back window rim is perfectly even.
      3. Place matchmarks over the back window and vehicle body.
        NOTE: Check that the stoppers are attached to the vehicle body correctly.

        HINT:

        When reusing the back window, check and correct the match-mark positions.

        Fig 5: Placing Matchmarks Over Back Window And Vehicle Body
        G03089164Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      4. Using suction cups, remove the back window.
    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 6: Applying Primer M To Exposed Part Of Vehicle Body Using Brush
        G03089165Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a brush or sponge, apply Primer G to the edge of the back window and contact surface.
      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 that which is specified, wipe off the primer with a clean shop rag before it dries.

        Fig 7: Applying Primer G To Edge Of Back Window And Contact Surface - Fixed Type
        G03089166Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        Fig 8: Applying Primer G To Edge Of Back Window And Contact Surface - Slide Type
        G03089167Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Apply adhesive.

      Adhesive: Part No. 08850-00801 or equivalent 

      1. 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 indicated in the table bellow.

        Usage time frame: 

        TEMPERATURE 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
      2. Load the sealer gun with the cartridge.
      3. Apply adhesive to the back window, as shown in the illustration.

        Specification: 

        TEMPERATURE SPECIFICATION

        Area Measurement
        a 6 mm (0.236 in.) or 8 mm (0.315 in.)
        b 8 mm (0.315 in.) or 12 mm (0.472 in.)
        Fig 9: Apply Adhesive To Back Window - Fixed Type
        G03089168Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        Fig 10: Apply Adhesive To Back Window - Slide Type
        G03089169Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the windshield glass onto the vehicle body.
      1. Using suction cups, position the back window 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 windshield glass have a small gap between them.
          Fig 11: Positioning Back Window Using Suction Cups
          G03089170Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Lightly press the front surface of the windshield glass to ensure that the windshield glass is securely fitted to the vehicle body.
      3. Using a scraper, remove any excessive or protruding adhesive.

        HINT:

        Apply adhesive onto the windshield glass rim.

        Fig 12: Applying Adhesive Onto Windshield Glass Rim
        G03089171Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Tighten the 2 nuts.

      Torque: 7.8 N.m (80 kgf.cm, 69 in.lbf) 

      Fig 13: Tightening Nuts
      G03089172Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. CHECK FOR LEAKAGE AND REPAIR 
    1. Conduct a leak test after the adhesive has completely hardened.
    2. Seal any leakage with auto glass sealer.
  36. INSTALL COAT HOOK 

    HINT:

  37. INSTALL QUARTER INSIDE TRIM BOARD LH 

    HINT:

  38. INSTALL QUARTER INSIDE TRIM BOARD RH 

    HINT:

    Follow the same procedures as for the quarter inside trim board LH.

  39. INSTALL ROOF SIDE GARNISH INNER LH (ACCESS CAB)  (See REPLACEMENT
  40. INSTALL ROOF SIDE GARNISH INNER RH (ACCESS CAB) 

    HINT:

    Follow the same procedures as for the roof side garnish inner LH.

  41. INSTALL QUARTER TRIM PANEL LOWER LH 

    HINT:

  42. INSTALL QUARTER TRIM PANEL LOWER RH 

    HINT:

    Follow the same procedures as for the quarter inside trim board LH.

  43. INSTALL LUGGAGE COMPARTMENT SIDE TRAY (DOUBLE CAB)  (See REPLACEMENT
  44. INSTALL REAR SEAT BACK HINGE SUB-ASSY CENTER (DOUBLE CAB)  (See OVERHAUL
  45. INSTALL LUGGAGE COMPARTMENT SIDE TRAY (DOUBLE CAB)  (See REPLACEMENT
  46. INSTALL BACK PANEL TRIM (ACCESS CAB, REGULAR CAB (SEPARATE SEAT TYPE)  (See REPLACEMENT
  47. INSTALL BACK PANEL TRIM COVER (REGULAR CAB (SEPARATE SEAT TYPE)  (See REPLACEMENT
  48. INSTALL JACK ASSY (REGULAR CAB (SEPARATE SEAT TYPE)  (See REPLACEMENT
  49. INSTALL BACK PANEL GARNISH UPPER (REGULAR CAB)  (See REPLACEMENT
  50. INSTALL BACK PANEL TRIM COVER (REGULAR CAB (BENCH SEAT TYPE)  (See REPLACEMENT
  51. INSTALL BACK PANEL TRIM COVER (EXCEPT DOUBLE CAB) 

    HINT:

  52. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH (DOUBLE CAB)  (See REPLACEMENT
  53. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP RH (DOUBLE CAB) 

    HINT:

    Follow the same procedures as for the rear door opening trim weatherstrip LH.

  54. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP LH (EXCEPT DOUBLE CAB) 

    HINT:

  55. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP RH (EXCEPT DOUBLE CAB) 

    HINT:

    Follow the same procedures as for the front door opening trim weatherstrip LH.

  56. INSTALL ROOF SIDE INNER GARNISH CAP LH (ACCESS CAB)  (See REPLACEMENT
  57. INSTALL ROOF SIDE INNER GARNISH CAP RH (ACCESS CAB) 

    HINT:

    Follow the same procedures as for the roof side inner garnish LH.

  58. INSTALL REAR DOOR SCUFF PLATE LH (EXCEPT REGULAR CAB) 

    HINT:

  59. INSTALL REAR DOOR SCUFF PLATE RH (EXCEPT REGULAR CAB) 

    HINT:

    Follow the same procedures as for the rear door scuff plate LH.

  60. INSTALL FRONT DOOR SCUFF PLATE LH (EXCEPT DOUBLE CAB) 

    HINT:

  61. INSTALL FRONT DOOR SCUFF PLATE RH (EXCEPT DOUBLE CAB) 

    HINT:

    Follow the same procedures as for the front door scuff plate LH.

  62. INSTALL REAR SEAT BACK HINGE SUB-ASSY LH (DOUBLE CAB)  (See OVERHAUL
  63. INSTALL REAR SEAT BACK HINGE SUB-ASSY RH (DOUBLE CAB)  (See OVERHAUL
  64. INSTALL REAR SEAT BACK ASSY LH (DOUBLE CAB)  (See OVERHAUL
  65. INSTALL REAR SEAT BACK ASSY RH (DOUBLE CAB)  (See OVERHAUL
  66. INSTALL REAR SEAT BACK HINGE COVER (DOUBLE CAB)  (See OVERHAUL
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