BACK DOOR GLASS INSTALLATION

PROCEDURE

  1. CLEAN BACK DOOR GLASS

    1. Using a scraper, remove the damaged spacers, moulding and adhesive sticking to the glass.

    2. B180599

      Clean the outer circumference of the glass with non-residue solvent.

      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 non-residue solvent.

  2. INSTALL NO. 1 BACK WINDOW GLASS SPACER

    1. Apply Primer G to the glass where the spacer will be installed.

      Note:

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

      • Throw away any leftover primer.

      • Do not apply too much primer.

      Tip:

      If the primer is applied to an area that is not specified, apply non-residue solvent to a clean cloth and wipe off the excess primer before it dries.

    2. B223735E04

      Remove the peeling paper from a new spacer. Install the spacer to the glass at the location shown in the illustration.

      Table 1. Text in Illustration

      *1

      Backside

      *2

      Marking for Spacer Installation

  3. INSTALL NO. 2 BACK WINDOW GLASS SPACER

    1. Apply Primer G to the glass where the spacer will be installed.

      Note:

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

      • Throw away any leftover primer.

      • Do not apply too much primer.

      Tip:

      If the primer is applied to an area that is not specified, apply non-residue solvent to a clean cloth and wipe off the excess primer before it dries.

    2. B223736E04

      Remove the peeling paper from a new spacer. Install the spacer to the glass at the location shown in the illustration.

      Table 2. Text in Illustration

      *1

      Backside

      *2

      Marking for Spacer Installation

  4. INSTALL BACK DOOR GLASS SPACER

    1. Apply Primer G to the glass where the spacers will be installed.

      Note:

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

      • Throw away any leftover primer.

      • Do not apply too much primer.

      Tip:

      If the primer is applied to an area that is not specified, apply non-residue solvent to a clean cloth and wipe off the excess primer before it dries.

    2. Remove the peeling paper from 2 new spacers. Install the 2 spacers to the glass at the locations shown in the illustration.

      B223737E04
      Table 3. Text in Illustration

      *1

      Backside

      *2

      Marking for Spacer Installation

  5. INSTALL BACK WINDOW OUTSIDE MOULDING

    1. Using a brush or sponge, coat the application area of the back window outside moulding with Primer G.

      B223738E04
      Table 4. Text in Illustration

      *1

      Backside

      *2

      Primer G

      Standard

      Area

      Specified Condition

      a

      13.0 mm (0.512 in.)
      Note:

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

      • Throw away any leftover primer.

      • Do not apply too much primer.

      Tip:

      If the primer is applied to an area that is not specified, apply non-residue solvent to a clean cloth and wipe off the excess primer before it dries.

    2. Remove the peeling paper from a new back window outside moulding. Install the moulding as shown in the illustration.

      U122501E01
      Table 5. Text in Illustration

      *1

      Backside

      *2

      Ceramic Notch

      Standard

      Area

      Specified Condition

      a

      12.5 mm (0.492 in.)

      b

      9.5 mm (0.374 in.)

      c

      Changes gradually from 9.5 to 12.5 mm (0.374 to 0.492 in.)

  6. INSTALL BACK DOOR GLASS

    B223733E01

    1. Position the glass.

      1. Using suction cups, place the glass in the correct position.

      2. Check that the entire contact surface of the glass rim is perfectly even.

      3. Place matchmarks on the glass and vehicle body on the locations indicated in the illustration.

        Table 6. Text in Illustration

        *1

        Matchmark
        Tip:

        • Placing matchmarks is only necessary when installing new glass. When reinstalling the used glass, matchmarks should already be present.

        • When reusing the glass, check and correct the matchmark positions.

        Note:

        Check that the spacers are contacting the vehicle body correctly.

      4. Using suction cups, remove the glass.

    2. B223740E02

      Using a brush or sponge, apply Primer M to the exposed part of the vehicle body.

      Note:

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

      • Do not apply primer to the adhesive.

      • Throw away any leftover primer.

      • Do not apply too much primer.

      Table 7. Text in Illustration

      *1

      CORRECT

      *2

      Primer M

      *3

      Adhesive

      *4

      INCORRECT

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

      B223741E02
      Table 8. Text in Illustration

      *1

      Backside

      *2

      Adhesive Center Line

      *3

      Primer G

      -

      -

      Standard

      Area

      Specified Condition

      a

      13.0 mm (0.512 in.)

      b

      7.0 mm (0.276 in.)

      c

      14.1 mm (0.564 in.)

      d

      12.0 mm (0.472 in.)
      Tip:

      If primer is applied to an area that is not specified, wipe off the primer with a non-residue solvent before it dries.

      Note:

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

      • Throw away any leftover primer.

      • Do not apply too much primer.

    4. Apply adhesive to the back door glass.

      Adhesive

      Toyota Genuine Windshield Glass Adhesive or equivalent

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

        Tip:

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

        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

      2. Load a sealer gun with the cartridge.

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

        B223742E02
        Table 9. Text in Illustration

        *1

        Backside

        *2

        Adhesive Center Line

        *3

        Adhesive

        -

        -

        Standard

        Area

        Specified Condition

        a

        12.0 mm (0.472 in.)

        b

        8.0 mm (0.315 in.)

        c

        13.0 mm (0.512 in.)

        d

        14.1 mm (0.564 in.)

    5. Install the back door glass to the vehicle body.

      1. Using suction cups, position the glass so that the matchmarks are aligned. Press it in gently along the rim.

      2. Lightly press the outer surface of the back door glass to ensure that the back door glass is securely fit to the vehicle body.

        Note:

        • Check that the spacers are contacting the vehicle body correctly.

        • Check that the vehicle body and glass have a small gap between them.

      3. Hold the back door glass securely in place with tape or equivalent until the adhesive has hardened.

      4. B180606E07

        Using a scraper, remove any excess or protruding adhesive.

        Table 10. Text in Illustration

        *1

        Adhesive
        Tip:

        Apply adhesive to any areas where the amount of adhesive is inadequate.

        Note:

        Do not drive the vehicle within the time written in the table below.

        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

      5. Connect the connectors.

  7. CHECK FOR LEAK AND REPAIR

    1. Conduct a leak test after the adhesive has completely hardened.

    2. If there are any leaks, seal them with auto glass sealer.

  8. INSTALL REAR WIPER MOTOR GROMMET

    Click here

  9. INSTALL REAR WIPER MOTOR AND BRACKET ASSEMBLY

    Click here

  10. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note:

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected (Click here).

  11. INSTALL REAR WIPER ARM

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  12. INSTALL REAR SPOILER SUB-ASSEMBLY

    Click here

  13. INSTALL NO. 2 BACK DOOR PANEL PROTECTOR

    Click here

  14. INSTALL NO. 1 BACK DOOR PANEL PROTECTOR

    Click here

  15. INSTALL BACK DOOR TRIM PANEL ASSEMBLY

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  16. INSTALL BACK DOOR INSIDE HANDLE

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  17. INSTALL BACK DOOR SIDE GARNISH LH

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  18. INSTALL BACK DOOR SIDE GARNISH RH

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  19. INSTALL CENTER BACK DOOR GARNISH

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