Back Window 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 torque specification is a standard bolt (see SPECIFIED TORQUE FOR STANDARD BOLTS ).

1. REMOVE REAR SEAT CUSHION ASSY (See  OVERHAUL  ) 
2. REMOVE REAR SEATBACK ASSY (See  OVERHAUL  ) 
3. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP RH 
4. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH 
5. REMOVE ROOF SIDE GARNISH INNER RH (w/o CURTAIN SHIELD AIR BAG) (See step 29 on  REPLACEMENT  ) 
6. REMOVE ROOF SIDE GARNISH INNER LH (w/o CURTAIN SHIELD AIR BAG) (See step 30 on  REPLACEMENT  ) 
7. REMOVE ROOF SIDE GARNISH INNER RH (w/ CURTAIN SHIELD AIR BAG) (See step 31 on  REPLACEMENT  ) 
8. REMOVE ROOF SIDE GARNISH INNER LH (w/ CURTAIN SHIELD AIR BAG) (See step 32 on  REPLACEMENT  ) 
9. REMOVE ROOF HEADLINING ASSY (See step 44 on  REPLACEMENT  ) 

   HINT:

   It is not necessary to completely remove the roof headlining. Slightly lower the rear section of the roof headlining so that the back window glass can be removed later in step 13.

10. REMOVE CENTER STOP LAMP ASSY (See  REPLACEMENT  ) 
11. REMOVE PACKAGE TRAY TRIM PANEL ASSY (See step 8 on  REPLACEMENT  and step 9 on  REPLACEMENT  ) 
12. REMOVE BACK WINDOW MOLDING OUTSIDE 
    1. Using a knife, cut off the molding, as shown in the illustration.
       NOTE: Be careful not to damage the vehicle body with the knife.
    2. Remove the remaining molding.

    HINT:

    Make a partial cut in the molding. Then pull and remove it by hand.

    Fig 1: Removing Back Window Molding Outside

    Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
13. REMOVE BACK WINDOW GLASS 

    HINT:

    In some cases, 1-piece type and 2-piece type stoppers are installed in the same vehicle.

    Fig 2: Identifying Stoppers

    Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
    1. From the interior, insert piano wires 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 3: Inserting Piano Wires Between Vehicle Body And Glass

       Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

       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. Disengage the stoppers.
    5. Using a suction cup, remove the glass.
    NOTE: Leave as much adhesive on the vehicle body as possible when removing the glass.
    Fig 4: Cutting Adhesive By Pulling Piano Wire Around Glass

    Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
14. CLEAN BACK WINDOW GLASS 
    1. Using a scraper, remove the damaged stoppers and adhesive sticking to the glass.
    2. Clean the outer circumference 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 5: Cleaning Back Window Glass

    Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
15. 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.

       2. Clean the contact surface of the vehicle body with a piece of shop rag saturated with cleaner.

       HINT:

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

       Fig 6: Cutting Away Rough Adhesive On Vehicle Body

       Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
16. INSTALL BACK WINDOW GLASS STOPPER NO. 2 
    1. Coat the installation part of the stopper with Primer G.
       NOTE:

       • Allow the primer coating to dry for 3 minutes or more.
       • Throw away any leftover Primer G,
       • Do not apply too much Primer G.
    2. Install 2 new stoppers onto the glass, as shown in the illustration.
    Fig 7: Installing Back Window Glass Stopper No. 2
    Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

    Specification: 

    STOPPER SPECIFICATION TABLE
    
    

    Area	Measurement
    A	11.2 mm (0.441 in.)
    B	40.0 mm (1.575 in.)

17. INSTALL BACK WINDOW GLASS STOPPER NO. 1 
    1. Install 2 new stoppers to the vehicle body, as shown in the illustration.
    Fig 8: Installing Back Window Glass Stopper No. 1

    Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
18. INSTALL BACK WINDOW MOLDING OUTSIDE 
    1. Using a brush or sponge, coat the edge of the glass and the contact surface with Primer G.
       NOTE:

       • Allow the primer coating to dry for 3 minutes or more.
       • Throw away any leftover Primer G.
       • Do not apply too much Primer G.
    2. Install the molding.
19. INSTALL BACK WINDOW GLASS 
    1. Position the glass.
       1. Using a suction cup, place the glass in the correct position.
       2. Check that the whole contact surface of the glass rim is perfectly even.
       3. Place reference marks between the glass and vehicle body.
          Fig 9: Placing Reference Marks Between Glass And Vehicle Body

          Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
          NOTE: Check that the stoppers are attached to the vehicle body correctly.

          HINT:

          When reusing the glass, check and correct the reference mark's positions.

       4. Using a suction cup, remove the glass.
    2. Using a brush, coat the exposed part of the vehicle body with Primer M.
       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.
       • Do not apply too much Primer M.
       Fig 10: Coating Vehicle Body With Primer M
       Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
    3. Using a brush or sponge, coat the edge of the glass and the contact surface with Primer G.

       HINT:

       If the area other than that specified is coated by accident, wipe off the primer with a clean shop rag 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 G.
    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 described in the table below.

          Usage time frame: 

          ADHESIVE - USAGE TIME FRAME TABLE
          
          

          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. Coat the glass with adhesive, as shown in the illustration.
       Fig 11: Coating Glass With Adhesive
       Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

       Specification: 

       ADHESIVE SPECIFICATION TABLE
       
       

       Area	Measurement
       a	8.0 mm (0.315 in.)
       b	12.0 mm (0.472 in.)
       c	6.5 mm (0.256 in.)

    5. Install the glass.
       1. Using a suction cup, position the glass so that the reference marks are aligned. Press it in gently along the rim.
          NOTE:

          • Allow the primer coating to dry for 3 minutes or more.
          • Check that the stoppers are attached to the vehicle body correctly.
          • Check that the vehicle body and glass have a small gap between them.
       2. Lightly press the front surface of the glass to ensure that the glass is securely fit to the vehicle body.
          Fig 12: Aligning Glass Reference Marks Using A Suction Cup

          Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
       3. Using a scraper, remove any excess or protruding adhesive.
       Fig 13: Removing Excess Adhesive Using A Scraper
       Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

       HINT:

       Apply adhesive on the glass rim.

       NOTE: Do not drive the vehicle for the amount of time described in the table below.

       Minimum time: 

       ADHESIVE - TIME PRIOR TO DRIVING VEHICLE TABLE
       
       

       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

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