Back Door Glass: Replacement

HINT:

The installation is in the reverse order of the removal. However, when there is a special point concerning the installation, it is indicated.

1. REMOVE BACK DOOR SERVICE HOLE PLATE (See  OVERHAUL  (BACK DOOR) or  OVERHAUL  (POWER BACK DOOR) ) 
   1. Remove the back door garnish center.
   2. Remove the back door side garnish LH.
   3. Remove the back door side garnish RH.
   4. Remove the back door strap cover.
   5. Remove the back door pull strap.
   6. Remove the back door rim board assy.
   7. Remove the back door service hole plate.
2. REMOVE REAR SPOILER COVER (w/ REAR SPOILER) (See  REAR SPOILER COVER  ) 
3. REMOVE REAR WIPER MOTOR AND BRACKET ASSY (See  REAR WIPER MOTOR AND BRACKET ASSY  ) 
   1. Remove the wiper arm head cap.
   2. Remove the rear wiper arm assy.
   3. Remove the wiper motor and bracket assy.
4. REMOVE BACK DOOR GLASS 
   1. Pass a piano wire between the body and glass from the interior.
      Fig 1: Passing Piano Wire Between Body And Glass From Interior

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Tie both wire ends to wooden blocks or similar objects.

      HINT:

      Apply protective tape to the outer surface to prevent the surface from being scratched.

      Fig 2: Applying Protective Tape To Outer Surface

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: When separating the glass, take care not to damage the paint and interior and exterior ornaments.
   3. Cut off the adhesive by pulling piano wire around it.
   4. Using a suction rubber, remove the glass.
   NOTE: Leave as much adhesive on the body as possible when removing the glass.
5. CLEAN BACK DOOR GLASS 
   1. Clean the outer circumference of the glass white gasoline.
   NOTE:

   • Do not touch the glass surface after cleaning it.
   • Be careful not to damage the body.
   Fig 3: Cleaning Back Door Glass

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. INSTALL BACK DOOR GLASS 
   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 body to ensure the appropriate surface shape.

         HINT:

         Leave as much adhesive on the body as possible.

         Fig 4: Cutting Away Any Rough Adhesive On Contact Surface

         Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Clean the contact surface of the body with a shop rag saturated with cleaner.

      HINT:

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

   2. Using a brush, coat the exposed part of the body on the vehicle side with Primer M.
      NOTE:

      • Allow the primer coating to dry for 3 minutes or more.
      • Do not coat the adhesive with Primer M.
      • Do not keep any of the opened Primer M for later use.
      Fig 5: Coating Exposed Part Of Body On Vehicle Side With Primer M Using Brush

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. 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.
      • Do not keep any of the opened Primer G for later use.
      Fig 6: Coating Edge Of Glass & Contact Surface With Primer G

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Dimensions: 

      GLASS DIMENSIONS
      
      

      a	15.0 mm (0.591 in.)
      b	15.0 mm (0.591 in.)
      c	20.0 mm (0.787 in.)
      d	30.0 mm (1.181 in.)
      e	15.0 mm (0.591 in.)

   4. Apply adhesive.

      Adhesive: Part No. 08850-00801 or equivalent 

      1. Cut off the tip of the cartridge nozzle as shown in Fig 7.

         HINT:

         After cutting off the tip, use all adhesive within the time described in TRACKFREE TIME  .

         Fig 7: Cutting Off Tip Of Cartridge Nozzle

         Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

         Tackfree time: 

         TRACKFREE TIME
         
         

         Temperature	Tackfree Time
         35°C (95°F)	15 minutes
         20°C (68°F)	100 minutes
         5°C (41°F)	8 hours

      2. Load the sealer gun with the cartridge.
      3. Coat the glass with adhesive as shown in Fig 7.

      Dimensions: 

      GLASS DIMENSIONS
      
      

      a	12.0 mm (0.472 in.)
      b	8.0 mm (0.315 in.)
      c	11.0 mm (0.433 in.)
      d	11.0 mm (0.433 in.)
      e	30.0 mm (1.181 in.)
      f	38.0 mm (1.496 in.)
      g	11.0 mm (0.433 in.)

   5. Install the glass to the body.
      1. Hold the back window glass in place securely with tape or equivalent to the body until the adhesive has hardened.
         NOTE:

         • Allow the primer coating to dry for 3 minutes or more.
         • Check that the clips are attached to the body correctly.
         • Check the clearance between the body and glass.
      2. Lightly press the front surface of the glass to ensure a close fit.
      3. Using a scraper, remove any excess or protruding adhesive.
      Fig 8: Removing Excess or Protruding Adhesive

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      Apply adhesive onto the glass rim.

      Fig 9: Applying Adhesive Onto Glass Rim

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Take care not to drive the vehicle for the time described in MINIMUM TIME  .

      Minimum time: 

      MINIMUM TIME
      
      

      Temperature	Minimum time prior to driving vehicle
      35°C (95°F)	1.5 hours
      20°C (68°F)	5 hours
      5°C (41°F)	24 hours

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