Back Window Glass: Replacement

HINT:

The installation procedures are the removal procedures in reverse order. However, only installation procedures requiring additional information are included.

REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH (SEE REPLACEMENT )
REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP RH (SEE REPLACEMENT )
REMOVE ROOF SIDE GARNISH ASSY INNER LH (SEE REPLACEMENT )
REMOVE ROOF SIDE GARNISH ASSY INNER RH (SEE REPLACEMENT )
REMOVE PACKAGE TRAY TRIM PANEL ASSY (SEE REPLACEMENT )
REMOVE ASSIST GRIP SUB-ASSY (SEE REPLACEMENT )
REMOVE REAR ROOM LIGHT ASSY (SEE REPLACEMENT )
REMOVE ROOF HEADLINING ASSY (SEE 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.
REMOVE BACK WINDOW MOLDING OUTSIDE UPPER
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:

Partially cut the molding. Then pull and remove it by hand.

Fig 1: Removing Back Window Molding Outside Upper
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BACK WINDOW GLASS
HINT:

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

Fig 2: Identifying 1 & 2 Piece Type Stoppers
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. From the interior, insert piano wires between the vehicle body and glass as shown in the illustration.
2. Tie wooden blocks or other objects that can serve as handles to all wire ends.
  
  Fig 3: Inserting Piano Wires Between Vehicle Body & 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.
  
  Fig 4: Applying Protective Tape To Outer Surface Of Vehicle Body
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
CLEAN BACK WINDOW GLASS
1. Using a scraper, remove the damaged stoppers the dam and any adhesive remaining on the glass.
2. Clean the outer circumference of the glass with white gasoline.
NOTE:
- Do not touch the glass after cleaning it.
- Even if using new glass, clean the glass with white gasoline.
Fig 5: Cleaning Back Window Glass
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 a proper fit.
    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 a shop rag or piece of cloth saturated with cleaner.
    
    Fig 6: Cleaning & Shaping Contact Surface Of Vehicle Body
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    HINT:
    
    Even if all the adhesive has been removed, clean the vehicle body.

INSTALL BACK WINDOW GLASS STOPPER NO.2

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

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

Specification:

AREA - MEASUREMENT

Area	Measurement
A	12.5 mm (0.492 in.)
B	50.0 mm (1.968 in.)

Fig 7: Installing Back Window Glass Stopper No. 2

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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, LICENSE AGREEMENT TMS1002
INSTALL BACK WINDOW MOLDING 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.
  - Dispose of any excess Primer G.
  - Do not apply too much Primer G.
2. Install the molding.

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 perfectly even.
3. Place reference marks on the glass and vehicle body.
  
  Fig 9: Installing Back Window Glass
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Check that the stoppers are attached to the vehicle body correctly.
  
  HINT:
  
  When reusing the glass, check and correct the reference mark positions.
4. Using a suction cup, remove the glass.
Using a brush, coat the exposed areas of the vehicle body, where all adhesive has been removed with Primer M.
NOTE:
- Allow the primer coating to dry for 3 minutes or more.
- Do not coat the area adhesive is still remaining with Primer M.
- Dispose of any excess Primer M.
- Do not apply too much Primer M.
Using a brush or sponge, coat the edge of the glass and the contact surface with Primer M.
HINT:

If a non-specified area is coated by accident, wipe off the primer with a clean a piece of cloth before it dries out.

Fig 10: Identifying Correct Way Of Applying Primer
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
NOTE:
- Allow the primer coating to dry for 3 minutes or more.
- Dispose of any excess Primer M.
- Do not apply too much Primer M.

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 adhesive within the time described in the table below.

Usage time frame:

USAGE TIME FRAME

Temperature	Usage time frame
35°C(95°F)	15 minutes
20°C (68°F)	1 hour 40 minutes
5°C(41°F)	8 hours

Load a sealer gun with the cartridge.

Coat the glass with adhesive as shown in the illustration.

Fig 11: Applying Adhesive

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Specification:

ADHESIVE AREA MEASUREMENT

Area	Measurement
a	8.0 mm (0.315 in.)
b	12.0 mm (0.472 in.)
c	7.0 mm (0.275 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.

Fig 12: Installing Glass
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 there is a small gap between the vehicle body and glass.
Lightly press the front surface of the glass to ensure that the glass is securely fit to the vehicle body.

Using a scraper, remove any excess adhesive.

HINT:

Make sure that adhesive is applied up to the glass rim.

NOTE: The vehicle should not be driven until the time indicated in the table below has elapsed after step (3).

Fig 13: Removing Adhesive

Minimum time:

MINIMUM TIME

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

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