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 a torque specification is shown in the standard bolt chart (see SUSPENSION CONTROL SYSTEM ).

REMOVE REAR SEAT CUSHION ASSY (see OVERHAUL )
REMOVE REAR SEATBACK ASSY (see OVERHAUL )
REMOVE ROOF HEADLINING ASSY
1. Remove the rear door scuff plate LH and RH.
2. Remove the rear door opening trim weatherstrip LH and RH.
3. Remove the rear seat side cover LH and RH.
4. Remove the roof side garnish inner LH and RH.
5. Remove the assist grip.
6. Remove the rear room lamp LH and RH.
7. Remove the vanity lamp LH and RH.
8. Partially remove the roof headlining.
  HINT:
  
  Do not remove the roof headlining completely. Slightly lower the rear section of the roof headlining so that the back window glass can be removed later in step 7.
REMOVE PACKAGE TRAY TRIM PANEL ASSY
1. Remove the rear speaker grille.
2. Remove the center stop lamp.
3. Remove the package tray trim panel.
w/ Rear sunshade:
REMOVE PACKAGE TRAY TRIM PANEL ASSY NO. 2
1. Remove the rear speaker grille.
2. Remove the package tray trim panel.
3. Remove the center stop lamp.
4. Remove the package tray trim panel No. 2.
REMOVE BACK WINDOW MOULDING OUTSIDE UPPER
1. Using a knife, cut off the moulding, as shown in the illustration.
  NOTE: Be careful not to damage the vehicle body with the knife.
2. Remove the remaining moulding.
  HINT:
  
  Make a partial cut in the moulding. Then pull and remove it by hand.
  
  Fig 1: Cutting Off Moulding Using A Knife
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BACK WINDOW GLASS
1. Disconnect the connector.
2. From the interior, insert piano wire between the vehicle body and glass, as shown in the illustration.
3. Tie object that can serve as handles (for example, wooden blocks) to all wire ends.
  
  Fig 2: Inserting Piano Wire 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.
4. Cut through the adhesive by pulling the piano wire around the glass.
5. Disengage the stoppers.
6. Using a suction cup, remove the glass.
  NOTE: Leave as much adhesive on the vehicle body as possible when removing the glass.
  
  Fig 3: Removing Glass Using Suction Cup
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 4: Cleaning Outer Circumference Of Glass With White Gasoline
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
    HINT:
    
    Leave as much adhesive on the vehicle body as possible.
    
    NOTE: Be careful not to damage the vehicle body.
  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 5: Cutting Away Any Rough Adhesive On Contact Surface Of Vehicle Body
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL WINDSHIELD GLASS STOPPER NO. 2

Coat the installation part of the stoppers 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.

Install 2 new stoppers onto the glass, as shown in the illustration.

Specification:

Fig 6: Installing Stoppers Onto Glass

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

AREA MEASUREMENT SPECIFICATIONS

Area	Measurement
A	12.4 mm (0.488 in.)
B	40.0 mm (1.574 in.)
C	12.5 mm (0.492 in.)

INSTALL WINDSHIELD GLASS STOPPER NO. 1
1. Install 2 new stoppers to the vehicle body, as shown in the illustration.
  
  Fig 7: Installing Stoppers To Vehicle Body
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BACK WINDOW MOULDING OUTSIDE UPPER
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 moulding.

INSTALL BACK WINDOW GLASS

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.
  HINT:
  
  When reusing the glass, check and correct the reference mark positions.
  
  NOTE: Check that the stoppers are attached to the vehicle body correctly.
4. Remove the glass.
  
  Fig 8: Placing Glass In Correct Position Using Suction Cup
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 9: Coating Exposed Part Of Vehicle Body With Primer M Using Brush
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using a brush or sponge, coat the edge of the glass and the contact surface with Primer G.
HINT:

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

Apply adhesive.

Adhesive: Part No. 08850-00801 or equivalent

Fig 11: Cutting Off Tip Of Cartridge Nozzle

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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 timeframe:

USAGE TIMEFRAME

Temperature	Usage Timeframe
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 the illustration.

Specification:

AREA MEASUREMENT SPECIFICATION

Area	Measurement
a	12.5 mm (0.492 in.)
b	8.0 mm (0.315 in.)
c	6.5 mm (0.256 in.)

Install the glass.

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.
Lightly press the front surface of the glass to ensure that the glass is securely fit to the vehicle body.

Fig 12: Positioning Glass So Reference Marks Are Aligned Using Suction Cup
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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 described in the table below.

Minimum time:

MINIMUM TIME PRIOR TO DRIVING VEHICLE

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 13: Removing Any Excess Or Protruding Adhesive Using Scraper

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