BACK DOOR GLASS INSTALLATION

PROCEDURE


  1. INSTALL NO. 3 BACK WINDOW GLASS SPACER


    1. Using a brush or sponge, coat the installation area of a new No. 3 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. A003PDCC02
      *A Back Side
      *a Ceramic Notch

      Install the new No. 3 back window glass spacer to the back window fix glass as shown in the illustration.

  2. INSTALL NO. 4 BACK WINDOW GLASS SPACER

    Tech Tips

    Use the same procedure as for the No. 3 back window glass spacer.

  3. INSTALL LOWER NO. 2 BACK WINDOW MOULDING


    1. Using a brush or sponge, coat the installation area of a new lower No. 2 back window moulding 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. A003PJEC02
      *A Back Side
      *a Back Window Fix Glass Edge Side

      Install the new lower No. 2 back window moulding to the back window fix glass as shown in the illustration.

      Standard Dimension
      Area Dimension
      a 6.7 mm (0.264 in.)

  4. INSTALL NO. 2 BACK WINDOW OUTSIDE MOULDING RH


    1. Using a brush or sponge, coat the installation area of a new No. 2 back window outside moulding RH 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. A003PBAC02
      *A Back Side
      *a Ceramic Notch

      Install the new No. 2 back window outside moulding RH to the back window fix glass as shown in the illustration.

      Standard Dimension
      Area Dimension
      a 2.1 mm (0.0827 in.)

  5. INSTALL NO. 2 BACK WINDOW OUTSIDE MOULDING LH

    Tech Tips

    Use the same procedure as for the RH side.

  6. INSTALL NO. 2 BACK DOOR GLASS ADHESIVE DAM


    1. A003PPCC02
      *a Cut

      Cut a new No. 2 back door glass adhesive dam so that it is the appropriate size as shown in the illustration.

      Standard Dimension
      Area Dimension
      a 79.9 to 80.9 cm (2.62 to 2.65 ft.)

    2. Using a brush or sponge, coat the installation area of the new No. 2 back door glass adhesive dam 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.

    3. A003PMPC02
      *A Back Side
      *a Ceramic Notch

      Install the No. 2 back door glass adhesive dam to the back window fix glass as shown in the illustration.

  7. INSTALL BACK WINDOW FIX GLASS SUB-ASSEMBLY


    1. A003PSJC02
      *a Matchmark

      Position the back window fix glass sub-assembly.


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

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

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

        Note

        Check that the No. 3 and No. 4 back window glass spacers are engaged to the back door panel correctly.

      4. Remove the back window fix 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.

      A003PEIC02
      *A Back Side - -
      *a Adhesive Positioning Center *b Ceramic Notch
      B004PFI Primer G - -
      Standard Dimension
      Area Dimension
      a 11.0 mm (0.433 in.) or more
      b 7.0 mm (0.276 in.) or more
      c 8.0 mm (0.315 in.)
      d 7.0 mm (0.276 in.) or more
      e 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


      • Apply primer G to the ceramic notches.

      • 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 back window fix glass sub-assembly.

      Adhesive
      Toyota Genuine Windshield Glass Adhesive or equivalent

      1. A003PQAC28
        *a Nozzle

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

        Standard Dimension
        Area Dimension
        a 12.0 to 15.0 mm (0.472 to 0.591 in.)
        b 8.0 to 11.0 mm (0.315 to 0.433 in.)

      2. Load the sealer gun with the cartridge.

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

        A003PBVC02
        *A Back Side - -
        *a Adhesive Positioning Center *b Ceramic Notch
        B004PFI Adhesive - -
        Standard Dimension
        Area Dimension
        a 8.3 mm (0.327 in.)
        b 8.0 mm (0.315 in.)
        c 10.8 mm (0.425 in.)

        Tech Tips

        Apply adhesive to the ceramic notches.

    5. Install the back window fix glass sub-assembly.


      1. A003PSJC02
        *a Matchmark

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

        Note


        • Check that the No. 3 and No. 4 back window glass spacers are engaged to the back door panel correctly.

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

      2. Lightly press the outer surface of the back window fix 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 window fix glass sub-assembly using protective tape until the applied adhesive becomes hard.

        Tech Tips

        Follow the instructions supplied by the adhesive manufacturer or in the corresponding instruction manual for the minimum amount of time necessary to wait before driving the vehicle.

    6. Connect each connector.

  8. INSTALL BACK DOOR OUTSIDE GARNISH SUB-ASSEMBLY

    Click here

  9. INSTALL BACK DOOR GLASS SPACER


    1. Using a brush or sponge, coat the installation area of the new back door 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. A003PH7C01
      *A Back Side
      *a Ceramic Notch

      Install the back door glass spacer to the back door glass as shown in the illustration.

  10. INSTALL BACK DOOR GLASS ADHESIVE DAM


    1. A003PPCC02
      *a Cut

      Cut a new back door glass adhesive dam so that it is the appropriate size as shown in the illustration.

      Standard Dimension
      Area Dimension
      a 95.0 to 96.0 cm (3.12 to 3.15 ft.)

    2. Using a brush or sponge, coat the installation area of the new back door glass adhesive dam 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.

    3. A003PNLC02
      *A Back Side
      *a Ceramic Notch

      Install the back door glass adhesive dam to the back door glass as shown in the illustration.

  11. INSTALL NO. 1 BACK WINDOW GLASS SPACER


    1. Using a brush or sponge, coat the installation 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. A003PF1C02
      *A Back Side
      *a Ceramic Notch
      *b Edge Of Curved Surface

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

      Standard Dimension
      Area Dimension
      a 71.0 mm (2.80 in.)
      b 98.8 mm (3.89 in.)

  12. INSTALL NO. 2 BACK WINDOW GLASS SPACER

    Tech Tips

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

  13. INSTALL BACK DOOR WINDOW MOULDING


    1. Using a brush or sponge, coat the installation area of a new back door window moulding 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. A003PE3C02
      *A Back Side

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

      Standard Dimension
      Area Dimension
      a 7.9 mm (0.311 in.)
      b 7.0 mm (0.276 in.)

  14. INSTALL BACK DOOR GLASS SUB-ASSEMBLY


    1. A003PQ7C02
      *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 engaged 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.

      A003PHJC02
      *A Back Side - -
      *a Adhesive Positioning Center *b Ceramic Notch
      B004PFI Primer G - -
      Standard Dimension
      Area Dimension
      a 7.0 mm (0.276 in.) or more
      b 16.9 mm (0.665 in.)
      c 7.0 mm (0.276 in.) or more
      d 7.0 mm (0.276 in.) or more
      e 43.7 mm (1.72 in.)
      f 7.0 mm (0.276 in.) or more
      g 7.0 mm (0.276 in.) or more
      h 16.9 mm (0.665 in.)
      i 25.0 mm (0.984 in.)
      j 4.0 mm (0.157 in.) or more
      k 7.0 mm (0.276 in.) or more
      l 12.1 mm (0.476 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


      • Apply primer G to the ceramic notches.

      • 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 back door glass sub-assembly.

      Adhesive
      Toyota Genuine Windshield Glass Adhesive (High modulus type) or equivalent

      1. A003PQAC28
        *a Nozzle

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

        Standard Dimension
        Area Dimension
        a 12.0 to 15.0 mm (0.472 to 0.591 in.)
        b 8.0 to 11.0 mm (0.315 to 0.433 in.)

      2. Load the sealer gun with the cartridge.

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

        A003PJXC02
        *A Back Side - -
        *a Adhesive Positioning Center *b Ceramic Notch
        B004PFI Adhesive - -
        Standard Dimension
        Area Dimension
        a 16.9 mm (0.665 in.)
        b 43.7 mm (1.72 in.)
        c 16.9 mm (0.665 in.)
        d 25.0 mm (0.984 in.)
        e 12.1 mm (0.476 in.)

        Tech Tips

        Apply adhesive to the ceramic notches.

    5. Install the back door glass sub-assembly.


      1. A003PQ7C02
        *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 engaged to the back door panel correctly.

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

      2. Lightly press the outer 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.

        Tech Tips

        Follow the instructions supplied by the adhesive manufacturer or in the corresponding instruction manual for the minimum amount of time necessary to wait before driving the vehicle.

    6. Connect each connector and engage each clamp.

    7. When replacing the back door glass sub-assembly with a new one:


      1. Connect the rear washer hose and engage the clamp.

  15. INSTALL REAR WASHER NOZZLE

    Tech Tips

    When reusing the back door glass.

    Click here

  16. INSTALL REAR WIPER MOTOR ASSEMBLY

    Click here

  17. INSPECT FOR LEAK


    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.

  18. INSTALL REAR SPOILER

    Click here