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 TRIM BOARD (SEE  OVERHAUL  ) 
   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 tool box panel sub-assy upper.
   5. Remove the tool set.
   6. Remove the assist grip assy.
   7. Remove the back door trim board.
   8. Remove the service hole cover.
2. REMOVE REAR WIPER ARM ASSY (SEE  REAR WIPER MOTOR ASSY  ) 
   1. Remove the wiper arm head cap.
   2. Remove the rear wiper arm assy.
3. REMOVE REAR WIPER MOTOR ASSY (SEE  REAR WIPER MOTOR ASSY  ) 
   1. Remove the wiper motor assy.
4. REMOVE BACK DOOR GLASS 
   1. Pass a piano wire between the body and glass from the interior.
   2. Tie both wire ends to wooden blocks or similar objects.
      Fig 1: Passing Piano Wire Between Body & Glass From Interior

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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.
      • To prevent the safety pad from being scratched when removing the glass, place a plastic sheet between the piano wire and safety pad.
   3. Cut off the adhesive by pulling the 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.
      Fig 2: Applying Protective Tape To Outer Surface

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. CLEAN BACK DOOR GLASS 
   1. Clean the outer circumference of the glass unleaded gasoline.
   NOTE:

   • Do not touch the glass surface after cleaning it.
   • Be careful not to damage the body.
     Fig 3: Cleaning Outer Circumference Of Glass Unleaded Gasoline

     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.

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

         HINT:

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

         Fig 4: Removing Any Rough Adhesive On Contact Surface Of Body

         Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   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 And Contact Surface With Primer G Using Brush Or Sponge

        Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Dimensions: 

      DIMENSIONS SPECIFICATION
      
      

      A	12.0 mm (0.472 in.)
      B	13.0 mm (0.512 in.)
      C	33.6 mm (1.323 in.)
      D	13.0 mm (0.512 in.)
      E	14.0 mm (0.551 in.)
      F	11.0 mm (0.433 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 TEMPERATURE SPECIFICATION .

         Tack free time: 

         TEMPERATURE SPECIFICATION
         
         

         Temperature	Tack free 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.
         Fig 7: Cutting Off Tip Of Cartridge Nozzle

         Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Dimensions: 

      DIMENSIONS SPECIFICATION
      
      

      A	12.0 mm (0.472 in.)
      B	8.0 mm (0.315 in.)
      C	12.0 mm (0.472 in.)
      D	13.0 mm (0.512 in.)
      E	29.6 mm (1.166 in.)
      F	37.6 mm (1.480 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 Any Excess Or Protruding Adhesive Using Scraper

         Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

         HINT:

         Apply adhesive onto the glass rim.

         NOTE: The vehicle should not be driven until the time indicated in TEMPERATURE SPECIFICATION  has elapsed.

      Minimum time: 

      TEMPERATURE SPECIFICATION
      
      

      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

      Fig 9: Applying Adhesive Onto Glass Rim

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.