BACK DOOR GLASS(for Hatchback) INSTALLATION

PROCEDURE


  1. INSTALL NO. 1 BACK WINDOW GLASS SPACER


    1. Using a brush or sponge, coat the application area of a new No. 1 back window glass spacer with primer G.

      Note


      • Do not apply too much primer G.

      • Allow the primer G to dry for 3 minutes or more.

      • Throw away any leftover primer G.

      Tech Tips

      If an area other than specified is coated by accident, wipe off the primer G with a clean piece of cloth before it dries.

    2. A01KRZVC02
      *A Back Side
      *a Ceramic Notch

      Install the new No. 1 back window glass spacer onto the back door glass as shown in the illustration.

  2. INSTALL NO. 2 BACK WINDOW GLASS SPACER

    Tech Tips

    Use the same procedure as for the No. 1 back window glass spacer.

  3. INSTALL BACK DOOR WINDOW MOULDING


    1. A01KSAAC02
      *A Back Side
      A01KSBW Primer G

      Using a brush or sponge, coat the application area of a new back door window moulding with primer G.

      Standard Dimension
      Area Dimension
      a 4.0 mm (0.157 in.)
      b 6.0 mm (0.236 in.)

      Note


      • Do not apply too much primer G.

      • Allow the primer G to dry for 3 minutes or more.

      • Throw away any leftover primer G.

      Tech Tips

      If an area other than specified is coated by accident, wipe off the primer G with a clean piece of cloth before it dries.

    2. A01KRAWC02
      *A Back Side

      Install the new back door window moulding onto the back door glass as shown in the illustration.

      Standard Dimension
      Area Dimension
      a 6.8 mm (0.268 in.)

  4. INSTALL LOWER BACK WINDOW MOULDING


    1. A01KSUMC02
      *A Back Side
      A01KSBW Primer G

      Using a brush or sponge, coat the application area of a new lower back window moulding with primer G.

      Standard Dimension
      Area Dimension
      a 4.0 mm (0.157 in.)
      b 6.4 mm (0.252 in.)

      Note


      • Do not apply too much primer G.

      • Allow the primer G to dry for 3 minutes or more.

      • Throw away any leftover primer G.

      Tech Tips

      If an area other than specified is coated by accident, wipe off the primer G with a clean piece of cloth before it dries.

    2. A01KTDUC02
      *A Back Side

      Install the new lower back window moulding onto the back door glass as shown in the illustration.

      Standard Dimension
      Area Dimension
      a 7.4 mm (0.291 in.)

  5. INSTALL BACK DOOR GLASS SUB-ASSEMBLY


    1. A01KRDCC03
      *a Matchmark

      Position the back door glass sub-assembly.


      1. Using suction cups, place the back door glass sub-assembly in the correct position.

      2. Check that the whole contact surface of the back door glass sub-assembly rim is perfectly even.

      3. Align the matchmarks on the back door glass sub-assembly and back door panel.

        Note

        Check that the No. 1 and No. 2 back window glass spacers are installed to the back door panel correctly.

      4. Remove the back door glass sub-assembly.

    2. Using a brush, coat the installation surfaces on the back door panel with primer M.

      Note


      • Do not coat the adhesive with primer M.

      • Do not apply too much primer M.

      • Allow the primer M to dry for 3 minutes or more.

      • Throw away any leftover primer M.

      Tech Tips

      If an area other than specified is coated by accident, wipe off the primer M with a clean piece of cloth before it dries.

    3. Using a brush or sponge, coat the adhesive application area with primer G.

      A01KT29C02
      *A Back Side - -
      A01KSBW Primer G - -
      Standard Dimension
      Area Dimension
      a 11.0 mm (0.433 in.) or more
      b 11.0 mm (0.433 in.) or more
      c 11.0 mm (0.433 in.) or more
      d 63.6 mm (2.50 in.) or less
      e 22.0 mm (0.866 in.) or more
      f 63.6 mm (2.50 in.) or less
      g 11.0 mm (0.433 in.) or more
      h 11.0 mm (0.433 in.) or more

      Note


      • Do not apply too much primer G.

      • Allow the primer G to dry for 3 minutes or more.

      • Throw away any leftover primer G.

      Tech Tips

      If an area other than specified is coated by accident, wipe off the primer G with a clean piece of cloth before it dries.

    4. Apply adhesive to the glass.

      Adhesive
      Toyota Genuine Windshield Glass Adhesive or equivalent

      1. A01KS1GC28
        *a Nozzle

        Cut off the tip of the cartridge nozzle as shown in the illustration.

        Standard Dimension
        Area Dimension
        a 12.0 mm (0.472 in.)
        b 8.0 mm (0.315 in.)

        Tech Tips

        After cutting off the tip, use all adhesive within the time described in the table below.

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

      2. Load the sealer gun with the cartridge.

      3. Apply adhesive to the back door glass sub-assembly as shown in the illustration.

        A01KTWMC02
        *A Back Side - -
        A01KSBW Adhesive - -
        Standard Dimension
        Area Dimension
        a 9.5 mm (0.374 in.)
        b 9.5 mm (0.374 in.)
        c 66.6 mm (2.62 in.)
        d 8.0 mm (0.315 in.) or more
        e 66.6 mm (2.62 in.)
        f 10.1 mm (0.402 in.)
        g 10.2 mm (0.374 in.)

    5. Install the back door glass sub-assembly.


      1. A01KRDCC03
        *a Matchmark

        Using suction cups, position the back door glass sub-assembly so that the matchmarks are aligned, and press it in gently along the rim.

        Note


        • Check that the No. 1 and No. 2 back window glass spacers are installed to the back door panel correctly.

        • Check the clearance between the back door panel and back door glass sub-assembly.

      2. Lightly press the front surface of the back door glass sub-assembly to ensure a close fit.

        Tech Tips

        Press the glass with force of 98 N (10 kgf, 22.0 lbf) or more.

      3. Using a scraper, remove any excess or protruding adhesive.

      4. Hold the back door glass sub-assembly using protective tape until the applied adhesive becomes hard.

        Note

        Do not drive the vehicle for the time described in the table below.

        Minimum Time
        Temperature Minimum Time Prior to Driving Vehicle
        35°C (95°F) 7 hours
        20°C (68°F) 12 hours
        5°C (41°F) 52 hours

    6. Connect each connector.

  6. INSTALL BACK DOOR PANEL NO. 2 PROTECTOR (w/ Back Door Panel Protector)

    Click here

  7. INSTALL BACK DOOR PANEL NO. 1 PROTECTOR (w/ Back Door Panel Protector)

    Tech Tips

    Use the same procedure as for the back door panel No. 2 protector.

  8. INSPECT FOR LEAKS AND REPAIR


    1. After the adhesive has hardened, apply water from the outside of the vehicle. Check that no water leaks into the cabin.

    2. If water leaks into the cabin, allow the water to dry and add adhesive.

    3. Remove the protective tape.

  9. INSTALL CENTER STOP LIGHT ASSEMBLY

    Click here

  10. INSTALL REAR WIPER MOTOR ASSEMBLY (w/ Rear Wiper)

    Click here

  11. INSTALL BACK DOOR OUTSIDE GARNISH

    Click here