RM38T0EC _59 Vehicle Exterior _115107 WINDOW / GLASS _0510343 BACK DOOR GLASS A

WINDOW / GLASS  BACK DOOR GLASS  INSTALLATION  


CAUTION / NOTICE / HINT

COMPONENTS (INSTALLATION)
B582011
3.198,0.646 3.5,0.646 false 1.479,1.198 1.688,1.198 false 1.031,1.99 1.24,1.99 false 0.75,3.469 0.958,3.469 false 4.854,5.115 5.063,5.115 false 5.625,3.615 5.896,3.615 false 6.073,2.375 6.271,2.375 false 5.531,2.948 5.646,2.948 false 6.646,0.292 6.844,0.292 false 4.875,1.208 5.073,1.208 false 4.24,0.958 4.24,1.115 false 1.083,1.094 1.24,1.292 0.156,0.198 10 false ● 1.563,1.854 1.719,2.052 0.156,0.198 10 false ● 1.271,3.323 1.427,3.521 0.156,0.198 10 false ● 6.167,3.51 6.323,3.708 0.156,0.198 10 false ● 6.552,2.26 6.708,2.458 0.156,0.198 10 false ● 5.354,1.083 5.51,1.281 0.156,0.198 10 false ● 4.198,1.135 4.354,1.333 0.156,0.198 10 false ● 2.469,1.125 2.74,1.323 0.271,0.198 10 false x2 1.25,1.052 1.438,1.344 0.188,0.292 18 false 3 1.719,1.813 1.906,2.104 0.188,0.292 18 false 4 1.406,3.281 1.594,3.573 0.188,0.292 18 false 2 5.125,4.948 5.313,5.24 0.188,0.292 18 false 9 6.313,3.469 6.5,3.76 0.188,0.292 18 false 6 5.938,2.781 6.125,3.073 0.188,0.292 18 false 7 6.698,2.208 6.885,2.5 0.188,0.292 18 false 2 5.5,1.021 5.688,1.313 0.188,0.292 18 false 5 4.365,1.083 4.552,1.375 0.188,0.292 18 false 3 3.563,0.469 3.75,0.76 0.188,0.292 18 false 8 6.063,0.135 6.667,0.427 0.604,0.292 18 false 1, 10

Procedure Part Name Code
Z101186

Z101188

Z101187

1 CLEAN BACK DOOR GLASS SUB-ASSEMBLY 68131 (Click here) - -
2 BACK DOOR WINDOW FRAME SPACER 68699 (Click here) - -
3 NO. 2 BACK DOOR GLASS ADHESIVE DAM 68294D (Click here) - -
4 NO. 2 BACK WINDOW GLASS SPACER 64819B (Click here) - -
5 NO. 1 BACK WINDOW GLASS SPACER 64818B (Click here) - -
6 BACK DOOR WINDOW GLASS ADHESIVE DAM 64813B (Click here) - -
7 BACK DOOR GLASS SUB-ASSEMBLY - (Click here) - -
8 CENTER STOP LIGHT ASSEMBLY 81006 - - -
9 REAR WIPER MOTOR GROMMET 85143R - - -
10 INSPECT FOR LEAK - (Click here) - -

● Non-reusable part - -

CAUTION / NOTICE / HINT

NOTICE:

Make sure to use Toyota Genuine Windshield Glass Adhesive (High Modulus Type) or equivalent.


PROCEDURE

Hide 68131 1.CLEAN BACK DOOR GLASS SUB-ASSEMBLY

a.
B590207N01
1.469,0.219 1.75,0.521 0.281,0.302 18 false i 4.594,0.24 4.875,0.542 0.281,0.302 18 false ii

i.

When reusing the back door glass sub-assembly.

1. Using a scraper, remove any remaining adhesive residue from the back door glass sub-assembly.

NOTICE:

Be careful not to damage the back door glass sub-assembly.



ii.

Clean the outer circumference of the back door glass sub-assembly with a non-residue solvent.

NOTICE:
·

Do not touch the back door glass sub-assembly surface after cleaning it.

·

Even if using a new back door glass sub-assembly, clean it with a non-residue solvent.





Hide 68699 2.INSTALL BACK DOOR WINDOW FRAME SPACER

a.
B582020
1.385,1.167 1.198,0.938 1.198,0.938 1.438,0.74 false 1.198,0.938 1.323,0.958 false 5.802,1.156 6,0.958 6,0.958 5.771,0.74 false 5.875,0.958 6,0.958 false 1,0.75 1.229,0.625 false 5.958,0.615 6.208,0.719 false 2.177,0.219 2.49,0.375 0.313,0.156 10 false *a 1.042,0.833 1.354,0.99 0.313,0.156 10 false *b 0.813,0.042 1.063,0.333 0.25,0.292 18 false i 6.01,0.875 6.323,1.031 0.313,0.156 10 false *b 1.115,1.292 1.271,1.49 0.156,0.198 10 false a 6.021,1.281 6.177,1.479 0.156,0.198 10 false a 1.26,0.51 1.573,0.708 0.313,0.198 10 false *c 5.792,0.531 6.104,0.729 0.313,0.198 10 false *c
*a Back Side of Back Door Glass Sub-assembly *b Ag Print Mark
*c Back Door Glass Sub-assembly Edge Side - -


i.

When reusing the back door glass sub-assembly.

1. Using a brush or sponge, coat the installation area of the back door window frame spacer with glass primer.

NOTICE:
·

Do not apply too much glass primer.

·

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

·

Throw away any leftover glass primer.



HINT:

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


2. Install 2 new back door window frame spacers to the back door glass sub-assembly as shown in the illustration.

Standard Dimension:
Area Dimension Area Dimension
a 20.5 to 24.5 mm (0.807 to 0.965 in.) - -




Hide 68294D 3.INSTALL NO. 2 BACK DOOR GLASS ADHESIVE DAM

a.
B582019
1.542,0.875 1.719,1.104 1.719,1.104 2,0.906 true 1.729,1.083 1.76,0.948 false 5.229,0.906 5.49,1.094 5.49,1.094 5.677,0.854 true 5.49,1.083 5.458,0.958 false 1.865,0.604 1.677,0.396 false 5.24,0.615 5.469,0.458 false 2.156,0.135 2.469,0.292 0.313,0.156 10 false *a 1.635,1.094 1.948,1.25 0.313,0.156 10 false *b 0.792,0.052 1.146,0.385 0.354,0.333 18 false i 5.406,1.115 5.719,1.271 0.313,0.156 10 false *b 1.229,0.594 1.385,0.792 0.156,0.198 10 false a 5.885,0.615 6.042,0.813 0.156,0.198 10 false a 1.521,0.313 1.833,0.51 0.313,0.198 10 false *c 5.5,0.323 5.813,0.521 0.313,0.198 10 false *c
*a Back Side of Back Door Glass Sub-assembly *b Ag Print Mark
*c Back Door Glass Sub-assembly Edge Side - -


i.

When reusing the back door glass sub-assembly.

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

NOTICE:
·

Do not apply too much glass primer.

·

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

·

Throw away any leftover glass primer.



HINT:

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


2. Install 2 new No. 2 back door glass adhesive dams to the back door glass sub-assembly as shown in the illustration.

Standard Dimension:
Area Dimension Area Dimension
a 9.0 to 13 mm (0.354 to 0.512 in.) - -




Hide 64819B 4.INSTALL NO. 2 BACK WINDOW GLASS SPACER

a.
B582018
5.135,1.229 5.146,1.052 false 1.052,0.354 1.365,0.51 0.313,0.156 10 false *a 0.906,0.031 1.24,0.333 0.333,0.302 18 false i 5.031,1.25 5.344,1.406 0.313,0.156 10 false *b
*a Back Side of Back Door Glass Sub-assembly *b Ag Print Mark


i.

When reusing the back door glass sub-assembly.

1. Using a brush or sponge, coat the installation area of the No. 2 back window glass spacer with glass primer.

NOTICE:
·

Do not apply too much glass primer.

·

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

·

Throw away any leftover glass primer.



HINT:

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


2. Install a new No. 2 back window glass spacer to the back door glass sub-assembly as shown in the illustration.



Hide 64818B 5.INSTALL NO. 1 BACK DOOR GLASS SPACER

Hide 64813B 6.INSTALL BACK DOOR WINDOW GLASS ADHESIVE DAM

a.
B582021
0.771,2.427 1.021,2 true 6.135,2.031 6.406,2.375 true 0.365,0.042 0.646,0.396 0.281,0.354 18 false i 0.594,2.385 0.792,2.552 0.198,0.167 10 true *b 6.417,2.385 6.656,2.573 0.24,0.188 10 false *b 1.51,0.073 1.823,0.271 0.313,0.198 10 false *a
*a Back Side of Back Door Glass Sub-assembly *b Ceramic Notch


i.

When reusing the back door glass sub-assembly.

1. Using a brush or sponge, coat the installation area of the back door window glass adhesive dam with glass primer.

NOTICE:
·

Do not apply too much glass primer.

·

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

·

Throw away any leftover glass primer.



HINT:

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


2. Install a new back door window glass adhesive dam to the back door glass sub-assembly as shown in the illustration.



Hide 7.INSTALL BACK DOOR GLASS SUB-ASSEMBLY

a.
B585856
0.396,0.052 0.677,0.406 0.281,0.354 18 false i
V100155

Adhesive - -


i.

Clean and shape the contact surface of the vehicle body.

1. Using a knife, cut away excess adhesive on the contact surface of the vehicle body as shown in the illustration.

NOTICE:

Leave as much adhesive on the vehicle body as possible.




b.
B582022
3.427,0.979 4.594,1.01 4.594,1.01 4.135,0.875 true 3.583,0.677 3.052,0.448 3.052,0.448 3.458,0.479 true 1.948,0.042 2.229,0.396 0.281,0.354 18 false i 4.646,0.927 4.833,1.135 0.188,0.208 10 true *b 2.833,0.333 3.042,0.521 0.208,0.188 10 true *a
*a Matchmark *b Suction Cup


i.

Prepare to install the back door glass sub-assembly by the below procedure.

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 vehicle body.

NOTICE:

Check that the back window glass spacers are engaged to the vehicle body correctly.


4. Remove the back door glass sub-assembly.


ii.

Using a brush, coat the installation surface on the vehicle body with body primer.

NOTICE:
·

Do not coat the adhesive with body primer.

·

Do not apply too much body primer.

·

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

·

Throw away any leftover body primer.



HINT:

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




c.
B603250
5.781,0.844 5.917,0.729 false 5.5,3.156 5.708,3.052 false 0.167,0.563 0.479,0.719 0.313,0.156 10 false *a 0.458,0.094 0.719,0.438 0.26,0.344 18 false i 1.906,0.667 2.063,0.865 0.156,0.198 10 true A 1.906,0.99 2.063,1.188 0.156,0.198 10 true A 0.979,0.635 1.135,0.833 0.156,0.198 10 true B 0.958,1.021 1.115,1.219 0.156,0.198 10 true B 0.781,0.927 0.938,1.125 0.156,0.198 10 true C 0.406,0.833 0.563,1.031 0.156,0.198 10 true C 1.896,1.833 2.052,2.031 0.156,0.198 10 true D 1.896,2.208 2.052,2.406 0.156,0.198 10 true D 1.25,2.708 1.708,2.906 0.458,0.198 10 false A-A 4.885,0.26 5.344,0.458 0.458,0.198 10 false B-B 4.323,1.26 4.781,1.458 0.458,0.198 10 false C-C 4.563,2.698 5.021,2.896 0.458,0.198 10 false D-D 2.26,2.531 2.417,2.729 0.156,0.198 10 false a 5.698,0.292 5.854,0.49 0.156,0.198 10 false b 5.281,1.594 5.438,1.792 0.156,0.198 10 false d 5.458,2.615 5.615,2.813 0.156,0.198 10 false e 5.552,1.365 5.708,1.563 0.156,0.198 10 false c 5.896,0.625 6.208,0.823 0.313,0.198 10 false *1 5.719,2.938 6.031,3.135 0.313,0.198 10 false *2
*1 No. 2 Back Door Glass Adhesive Dam *2 Back Door Window Glass Adhesive Dam
*a Back Side of Back Door Glass Sub-assembly - -
V100155

Glass Primer - -


i.

Using a brush or sponge, coat the adhesive application area with glass primer as shown in the illustration.

Standard Dimension:
Area Dimension Area Dimension
a 26.3 mm (1.04 in.) or more b 29.1 mm (1.15 in.) or more
c 80.4 mm (3.17 in.) or more d 58.4 mm (2.30 in.)
e 28.6 mm (1.13 in.) or more - -


NOTICE:
·

Do not apply too much glass primer.

·

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

·

Throw away any leftover glass primer.



HINT:
·

Apply glass primer onto the ceramic notches.

·

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





d.
B642103
3.229,0.667 3.073,0.573 false 5.667,2.865 5.781,2.74 false 5.625,5.188 5.49,5.083 false 0.125,2.531 0.438,2.688 0.313,0.156 10 false *b 0.458,0.125 0.708,0.458 0.25,0.333 18 false i 3.25,0.615 3.563,0.813 0.313,0.198 10 false *a 2.365,0.74 2.521,0.938 0.156,0.198 10 false a 3.219,1.583 3.375,1.781 0.156,0.198 10 false a 3.01,1.021 3.167,1.219 0.156,0.198 10 false b 2.625,1.156 2.781,1.354 0.156,0.198 10 false b 1.917,2.656 2.073,2.854 0.156,0.198 10 true A 1.927,3.021 2.083,3.219 0.156,0.198 10 true A 0.99,2.656 1.146,2.854 0.156,0.198 10 true B 0.969,3.042 1.125,3.24 0.156,0.198 10 true B 0.719,2.969 0.906,3.135 0.188,0.167 10 true C 0.375,2.885 0.531,3.083 0.156,0.198 10 true C 1.917,3.854 2.073,4.052 0.156,0.198 10 true D 1.948,4.219 2.104,4.417 0.156,0.198 10 true D 1.469,4.677 1.927,4.875 0.458,0.198 10 false A-A 4.927,2.24 5.385,2.438 0.458,0.198 10 false B-B 4.302,3.365 4.76,3.563 0.458,0.198 10 false C-C 4.802,4.594 5.26,4.792 0.458,0.198 10 false D-D 2.313,4.521 2.469,4.719 0.156,0.198 10 false c 5.646,2.354 5.802,2.552 0.156,0.198 10 false d 5.333,3.396 5.49,3.594 0.156,0.198 10 false e 5.49,4.583 5.646,4.781 0.156,0.198 10 false f 5.781,2.635 6.094,2.833 0.313,0.198 10 false *1 5.344,4.969 5.656,5.167 0.313,0.198 10 false *2 0.458,2.177 1.01,2.531 0.552,0.354 18 false ii
*1 No. 2 Back Door Glass Adhesive Dam *2 Back Door Window Glass Adhesive Dam
*a Cartridge Nozzle *b Back Side of Back Door Glass Sub-assembly
V100155

Adhesive - -


i.

Prepare to apply adhesive to the back door glass sub-assembly by the below procedure.

Adhesive:

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


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

Standard Dimension:
Area Dimension Area Dimension
a 12 to 15 mm (0.472 to 0.591 in.) b 8.0 to 11 mm (0.315 to 0.433 in.)


2. Load the sealer gun with the cartridge.


ii.

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

Standard Dimension:
Area Dimension Area Dimension
c 19.3 mm (0.760 in.) d 22.1 mm (0.870 in.)
e 65.2 mm (2.57 in.) f 21.6 mm (0.850 in.)




e.
B582025
3.115,1.063 3.104,1.365 3.104,1.365 3.833,0.865 true 3.875,1.385 4.333,1.292 4.333,1.292 3.74,1.156 true 1.969,0.135 2.25,0.49 0.281,0.354 18 false i 0.917,1.948 1.198,2.302 0.281,0.354 18 false ii 2.969,1.406 3.167,1.615 0.198,0.208 10 true *a 4.354,1.219 4.583,1.417 0.229,0.198 10 true *b
*a Suction Cup *b Matchmark


i.

Install the back door glass sub-assembly by the below procedure.

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

NOTICE:
·

Check that the back window glass spacers are engaged to the vehicle body correctly.

·

Check the clearance between the vehicle body and back door glass sub-assembly.



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

HINT:

Press the glass with a 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.

HINT:

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.



ii.

Connect the 2 connectors.



Hide 81006 8.INSTALL CENTER STOP LIGHT ASSEMBLY

Hide 10.INSPECT FOR LEAK

a.
B582026
0.49,0.135 0.771,0.49 0.281,0.354 18 false i

i.

Inspect for leaks by the below procedure.

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.