Back Door Glass: Replacement

HINT:

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

REMOVE BACK DOOR GLASS
1. From the interior, insert piano wires between the vehicle body and glass, as shown in Fig 1.
  
  Fig 1: Inserting Piano Wires Between Vehicle Body And Glass
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Tie objects that can serve as handles (for example, wooden blocks) to all wire ends.
  HINT:
  
  Apply protective tape to the outer surface of the vehicle to prevent its surface from being scratched.
  
  Fig 2: Applying Protective Tape To Outer Surface Of Vehicle
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: When separating the glass from the vehicle, take care not to damage the paint and interior/exterior ornaments.
3. Cut through 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 edges of the glass with white gasoline.
  NOTE:
  - Do not touch the glass surface after cleaning it.
  - Be careful not to damage the glass.
  - Even if using new glass clean the glass with white gasoline.
  Fig 3: Cleaning Outer Edges Of Glass With White Gasoline
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL BACK WINDOW GLASS CLIP

Using a brush or sponge, apply Primer G to the installation part of the clips.

Install new clips.

NOTE:

Allow the primer coating to dry for 3 minutes or more.
Throw away any leftover Primer G.
Do not apply too much primer.

Specification:

BACK WINDOW GLASS CLIP INSTALLATION SPECIFICATIONS

Area	Measurement
a	528.8 mm (20.819 in.)
b	35.8 mm (1.409 in.)

Fig 4: Installing Back Window Glass Clip

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL BACK DOOR GLASS SPACER

Using a brush or sponge, apply Primer G to the installation part of the spacers.
Install new spacers.

NOTE:

Allow the primer coating to dry for 3 minutes or more.
Throw away any leftover Primer G.
Do not apply too much primer.

Specification:

BACK DOOR GLASS SPACER INSTALLATION SPECIFICATIONS

Area	Measurement
a	15.0 mm (0.591 in.)
b	220 mm (8.661 in.)
c	220 mm (8.661 in.)
d	18.0 mm (0.709 in.)

Fig 5: Installing Back Door Glass Spacer

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL BACK WINDOW MOULDING OUTSIDE

Apply Primer G to the installation part of the moulding outside.
NOTE:
- Allow the primer coating to dry for 3 minutes or more.
- Throw away any leftover Primer G.
- Do not apply too much primer.

Install new dams applying double-sided tape, as shown in Fig 6.

Specification:

BACK WINDOW MOULDING OUTSIDE INSTALLATION SPECIFICATIONS

Area	Measurement
A	3.0 mm (0.118 in.)

Fig 6: Installing Back Window Moulding Outside

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL BACK DOOR GLASS

Clean and shape the contact surface of the adhesive on the vehicle body.
1. Using a knife, cut away any excess or unneeded adhesive on the contact surface.
  HINT:
  
  Leave as much adhesive on the vehicle body as possible.
2. Clean the contact surface of the vehicle body with cleaner.
Fig 7: Cutting Away Any Excess Or Unneeded Adhesive On Contact Surface
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

Even if all the adhesive has been removed, clean the vehicle body.
Using a brush, apply Primer M to the exposed part of the vehicle body.
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.
Fig 8: Applying Primer M To Exposed Part Of Vehicle Body
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using a brush or sponge, apply Primer G to the contact surface of the glass.

HINT:

If Primer G is accidentally applied to another part of the vehicle, wipe off the primer with cleaner 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.

Specification:

PRIMER G APPLICATION SPECIFICATIONS

Area	Measurement
a	14.0 mm (0.551 in.)
b	10.0 mm (0.394 in.)
c	12.8 mm (0.504 in.)
d	30.0 mm (1.181 in.)
e	22.0 mm (0.866 in.)
f	38.0 mm (1.496 in.)

Fig 9: Applying Primer G To Exposed Part Of Vehicle Body

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Apply adhesive.

Adhesive: Part No. 08850-00801 or equivalent

Cut off the tip of the cartridge nozzle, as shown in Fig 10.

HINT:

After cutting off the tip, use all adhesive within the time written in ADHESIVE USAGE TIMEFRAME .

Usage Timeframe:

ADHESIVE 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.
Apply adhesive to the glass, as shown in Fig 10.

Specification:

ADHESIVE APPLICATION SPECIFICATIONS

Area	Measurement
a	8.0 mm (0.315 in.)
b	12.5 mm (0.492 in.)
c	10.0 mm (0.394 in.)
d	12.8 mm (0.504 in.)
e	30.0 mm (1.181 in.)
f	30.0 mm (1.181 in.)

Fig 10: Applying Adhesive To Glass

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.

Fig 11: Removing Any Excess Or Protruding Adhesive
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

Apply adhesive onto the glass rim.

NOTE: Do not to drive the vehicle within the time written in MINIMUM TIME SPECIFICATION .

Minimum time:

ADHESIVE SETTING TIMES

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