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.

REMOVE REAR WIPER ARM ASSY (See REAR WIPER MOTOR ASSY )
REMOVE BACK DOOR TRIM COVER (See OVERHAUL )
1. W/Power back door:
  Remove the back door trim board LH.
2. Remove the back door trim panel upper.
3. Remove the back door trim panel assy upper.
4. Remove the back door trim panel assy.
5. Remove the back door trim cover RH.
6. Remove the back door trim cover LH.
REMOVE REAR SPOILER (See REAR SPOILER )
REMOVE REAR WIPER MOTOR ASSY (See REAR WIPER MOTOR ASSY )
REMOVE REAR LAMP ASSY LH (See REAR COMBINATION LAMP ASSY LH )
REMOVE REAR LAMP ASSY RH (See REAR COMBINATION LAMP ASSY LH )
REMOVE BACK DOOR GLASS
1. Pass a piano wire between the vehicle body and glass from the interior.
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.
  
  NOTE: When separating the glass, take care not to damage the paint and interior and exterior ornaments.
  
  Fig 2: Applying Protective Tape To Outer Surface
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Cut off the adhesive by pulling the piano wire around the glass.
  NOTE: If the back door glass will be reused, be careful not to damage the clip attached to the glass when you cut off the adhesive.
4. Using a suction cup, remove the glass.
  NOTE: Leave as much adhesive on the vehicle body as possible when removing the glass.
CLEAN BACK DOOR GLASS
1. Clean the outer circumference of the glass with white gasoline.
  NOTE:
  - Do not touch the glass surface after cleaning it.
  - Be careful not to damage the glass.
  Fig 3: Cleaning Back Door Glass
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL BACK WINDOW MOULDING

Coat the installation part of the mouldings with Primer G.
NOTE:
- Allow the primer coating to dry for 3 minutes or more.
- Do not apply too much primer.

Install a new mouldings, applying double-sided tape all the way around the glass except where the mouldings is installed, as shown in the illustration.

Fig 4: Installing New Mouldings And Applying Double-Sided Tape

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard dimension:

STANDARD DIMENSION SPECIFICATION

Area	Dimension
a	8.0 mm (0.315 in.)
b	9.2 mm (0.362 in.)
c	9.2 mm (0.362 in.)

INSTALL BACK DOOR GLASS

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.
  
  Fig 5: Cutting Adhesive On Contact Surface Of Vehicle Body
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
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.
- Do not keep any of the opened Primer M for later use.
Fig 6: Coating Exposed Part Of Vehicle Body With Primer M
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.

Fig 7: Coating Edge Of Glass And Contact Surface With Primer G

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE:

Allow the primer coating to dry for 3 minutes or more.
Do not keep any of the opened Primer G for later use.

Standard dimension:

STANDARD DIMENSION SPECIFICATION

Area	Dimension
a	8.0 mm (0.315 in.)
b	9.2 mm (0.362 in.)
c	9.2 mm (0.362 in.)
d	8.0 mm (0.315 in.)
e	16.0 mm (0.630 in.)

Apply adhesive.

Adhesive: Part No. 08850-00801 or equivalent

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.

Tackfree time:

TACKFREE TIME TEMPERATURE SPECIFICATION

Temperature	Tackfree Time
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 lustration.

Fig 8: Coat Glass With Adhesive

Standard dimension:

STANDARD DIMENSION SPECIFICATION

Area	Dimension
a	12.0 mm (0.472 in.)
b	8.0 mm (0.315 in.)
c	8.0 mm (0.315 in.)
d	9.2 mm (0.362 in.)

Install the glass to the vehicle body.

Hold the back window glass in place securely with tape or equivalent to the vehicle 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 vehicle body correctly.
- Check the clearance between the vehicle body and glass.
Lightly press the front surface of the glass to ensure a close fit.

Using a scraper, remove any excess or protruding adhesive.

HINT:

Apply adhesive onto the glass rim.

NOTE: Take care not to drive the vehicle for the time described in the table below.

Fig 9: Applying Adhesive Onto Glass Rim

Minimum time:

MINIMUM TIME TEMPERATURE SPECIFICATION

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 AND REPAIR WATER-LEAK
1. Conduct a leak test after the adhesive has completely hardened.
2. Seal any leaks with auto glass sealer.