BACK DOOR GLASS

INSTALL NO. 2 QUARTER WINDOW GLASS SPACER

Using a brush or sponge, coat the installation area of a new No. 2 quarter 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.
*A Back Side

*a Matchmark

Install the 3 new No. 2 quarter window glass spacers to the back window fix glass as shown in the illustration.

INSTALL QUARTER WINDOW GLASS SPACER

Using a brush or sponge, coat the installation area of 2 new quarter window glass spacers 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.
*A Back Side

*a Matchmark

Install the 2 new quarter window glass spacers to the back window fix glass as shown in the illustration.

INSTALL NO. 3 BACK WINDOW GLASS SPACER

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.
*A Back Side

*a Matchmark

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

INSTALL NO. 4 BACK WINDOW GLASS SPACER

Tech Tips

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

INSTALL LOWER BACK WINDOW OUTSIDE MOULDING RH

Using a brush or sponge, coat the installation area of a new lower 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.

*A	Back Side
*a	Ceramic Notch
*b	Edge of Curved Surface

Install the new lower back window outside moulding RH to the back window fix glass as shown in the illustration.

Standard Dimension

Area	Dimension
a	4.2 to 6.8 mm (0.165 to 0.268 in.)

INSTALL LOWER BACK WINDOW OUTSIDE MOULDING LH

Tech Tips

Use the same procedure as for the RH side.

INSTALL BACK WINDOW FIX GLASS SUB-ASSEMBLY

*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.
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.

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

*A	Back Side	-	-
*a	Adhesive Positioning Center	*b	Ceramic Notch
	Primer G	-	-

Standard Dimension

Area	Dimension
a	4.0 to 5.5 mm (0.158 to 0.217 in.)
b	19.3 mm (0.760 in.)
c	7.0 mm (0.276 in.) or more
d	4.0 to 5.5 mm (0.158 to 0.217 in.)
e	16.1 mm (0.634 in.)
f	7.0 mm (0.276 in.) or more
g	4.0 to 5.5 mm (0.158 to 0.217 in.)
h	11.5 mm (0.453 in.)
i	7.0 mm (0.276 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.

Apply adhesive to the back window fix glass sub-assembly.

Adhesive
Toyota Genuine Windshield Glass Adhesive or equivalent

*a

Nozzle

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

Standard Dimension

Area	Dimension
a	12.0 to 14.0 mm (0.472 to 0.551 in.)
b	8.0 to 10.0 mm (0.315 to 0.394 in.)

Load the sealer gun with the cartridge.

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

*A	Back Side	-	-
*a	Adhesive Positioning Center	*b	Ceramic Notch
	Adhesive	-	-

Standard Dimension

Area	Dimension
a	19.3 mm (0.760 in.)
b	16.1 mm (0.634 in.)
c	11.5 mm (0.453 in.)

Tech Tips

Apply adhesive to the ceramic notches.

Install the back window fix glass sub-assembly.
1. *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.
Connect each connector.

INSTALL REAR LIGHT ASSEMBLY LH

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INSTALL REAR LIGHT ASSEMBLY RH

Tech Tips

Use the same procedure as for the LH side.

INSTALL NO. 2 BACK DOOR GLASS ADHESIVE DAM

Using a brush or sponge, coat the installation area of a 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.
*A Back Side

*a Matchmark

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

INSTALL BACK DOOR GLASS SPACER

Using a brush or sponge, coat the installation area of a 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.
*A Back Side

*a Matchmark

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

INSTALL BACK DOOR GLASS ADHESIVE DAM

*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	91.2 to 92.2 cm (2.99 to 3.02 ft.)

Using a brush or sponge, coat the installation area of the 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.
*A Back Side

*a Matchmark

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

INSTALL NO. 1 BACK WINDOW GLASS SPACER

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.

*A	Back Side
*a	Matchmark
*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	59 mm (2.32 in.)
b	140 mm (5.51 in.)

INSTALL NO. 2 BACK WINDOW GLASS SPACER

Tech Tips

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

INSTALL UPPER BACK WINDOW OUTSIDE MOULDING RH

Using a brush or sponge, coat the installation area of a new upper 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.

*A	Back Side
*a	Matchmark

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

Standard Dimension

Area	Dimension
a	3.0 mm (0.118 in.)
b	3.0 mm (0.118 in.)
c	13.9 mm (0.547 in.)
d	12.5 mm (0.492 in.)
e	7.0 mm (0.276 in.)

INSTALL UPPER BACK WINDOW OUTSIDE MOULDING LH

Tech Tips

Use the same procedure as for the RH side.

INSTALL BACK DOOR GLASS SUB-ASSEMBLY

*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.
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.

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

*A	Back Side	-	-
*a	Adhesive Positioning Center	*b	Ceramic Notch
	Primer G	-	-

Standard Dimension

Area	Dimension
a	7.0 mm (0.276 in.) or more
b	152.8 mm (6.02 in.)
c	7.0 mm (0.276 in.) or more
d	7.0 mm (0.276 in.) or more
e	7.0 mm (0.276 in.) or more
f	20.3 mm (0.799 in.)
g	7.0 mm (0.276 in.)
h	7.0 mm (0.276 in.) or more
i	7.0 mm (0.276 in.)
j	7.0 mm (0.276 in.) or more
k	20.3 mm (0.799 in.)
l	7.0 mm (0.276 in.)
m	7.0 mm (0.276 in.) or more
n	18.6 mm (0.732 in.)
o	25.8 mm (1.02 in.)
p	4.0 to 5.5 mm (0.158 to 0.217 in.)
q	18.6 mm (0.732 in.)
r	7.0 mm (0.276 in.) or more
s	4.0 to 5.5 mm (0.158 to 0.217 in.)
t	13.1 mm (0.516 in.)
u	7.0 mm (0.276 in.) or more
v	4.0 to 5.5 mm (0.158 to 0.217 in.)
w	13.0 mm (0.512 in.)
x	7.0 mm (0.276 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.

Apply adhesive to the back door glass sub-assembly.

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

*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.)

Load the sealer gun with the cartridge.

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

*A	Back Side	-	-
*a	Adhesive Positioning Center	*b	Ceramic Notch
	Adhesive	-	-

Standard Dimension

Area	Dimension
a	152.8 mm (6.02 in.)
b	20.3 mm (0.799 in.)
c	20.3 mm (0.799 in.)
d	18.6 mm (0.732 in.)
e	26.6 to 29.6 mm (1.05 to 1.17 in.)
f	18.6 mm (0.732 in.)
g	13.1 mm (0.516 in.)
h	13.0 mm (0.512 in.)

Tech Tips

Apply adhesive to the ceramic notches.

Install the back door glass sub-assembly.
1. *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.
Connect each connector and engage each clamp.

INSPECT FOR LEAK

After the adhesive has hardened, apply water from the outside of the vehicle. Check that no water leaks into the cabin.
If water leaks into the cabin, allow the water to dry and add adhesive.
Remove the protective tape.

INSTALL CENTER STOP LIGHT SET

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INSTALL BACK DOOR UPPER TRIM PANEL ASSEMBLY

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BACK DOOR GLASS INSTALLATION