RM35X0E _59 Vehicle Exterior _079318 WINDOW / GLASS _0400163 BACK DOOR GLASS(for Wagon) A

WINDOW / GLASS  BACK DOOR GLASS(for Wagon)  INSTALLATION  


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

a.

When reusing the back door glass:

i.
B149736

Using a gasket scraper, remove any remaining, clip, spacer, moulding, adhesive dam, double-sided tape and adhesive residue from the back door glass.

NOTICE:

Be careful not to damage the back door glass.




b.

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

NOTICE:
·

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

·

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




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

a.

Using a brush or sponge, apply the body primer to the No. 2 back window glass spacer installation surface of the back door panel.

NOTICE:

Do not apply too much primer.



b.

Remove the peeling paper from 2 new No. 2 back window glass spacers.

HINT:

After removing the peeling paper, keep the exposed adhesive free from foreign matter.



c.

Install the No. 2 back window glass spacer to the back door panel.

B544761C01
5.458,0.906 5.323,1.125 false 1.115,1.802 1.354,1.604 false 0.073,0.063 0.385,0.26 0.313,0.198 10 false *a 4.448,0.792 4.604,0.99 0.156,0.198 10 false a 0.552,1.823 0.708,2.021 0.156,0.198 10 false b 5.198,1.156 5.51,1.354 0.313,0.198 10 false *1 1.427,1.448 1.854,1.656 0.427,0.208 10 false *1
*1 Back Door Panel - -
*a Backside - -
V100155

No. 2 Back Window Glass Spacer - -


NOTICE:

Allow the primer to dry for 3 minutes or more.


Standard Dimension:
Area Dimension

*A: for Standard Roof

*B: for High Roof

a*A 2.4 mm (0.0945 in.)
a*B 2.8 mm (0.110 in.)
b 6.5 mm (0.256 in.)



Hide 64828 3.INSTALL BACK WINDOW GLASS CLIP LH

a.

Using a brush or sponge, apply the glass primer to the back window glass clip LH installation surface of the back door glass.

NOTICE:

Do not apply too much primer.



b.

Remove the peeling paper from a new back window glass clip LH.

HINT:

After removing the peeling paper, keep the exposed adhesive free from foreign matter.



c.

Install the back window glass clip LH to the back door glass as shown in the illustration.

B537109C01
6.146,0.365 6.406,0.198 true 0.135,0.094 0.448,0.25 0.313,0.156 10 false *a 6.458,0.125 6.771,0.281 0.313,0.156 10 false *b
*a Backside *b Ceramic Notch


NOTICE:

Allow the primer to dry for 3 minutes or more.



Hide 64827A 4.INSTALL BACK WINDOW GLASS CLIP RH

a.

Using a brush or sponge, apply the glass primer to the back window glass clip RH installation surface of the back door glass.

NOTICE:

Do not apply too much primer.



b.

Remove the peeling paper from a new back window glass clip RH.

HINT:

After removing the peeling paper, keep the exposed adhesive free from foreign matter.



c.

Install the back window glass clip RH to the back door glass as shown in the illustration.

B537110C01
0.688,0.208 0.427,0.333 true 0.042,0.021 0.354,0.177 0.313,0.156 10 false *a 0.75,0.135 1.063,0.292 0.313,0.156 10 false *b
*a Backside *b Ceramic Notch


NOTICE:

Allow the primer to dry for 3 minutes or more.



Hide 64819C 5.INSTALL NO. 2 BACK DOOR GLASS SPACER

a.

Using a brush or sponge, apply the glass primer to the No. 2 back door glass spacer installation surface of the back door glass.

NOTICE:

Do not apply too much primer.



b.

Remove the peeling paper from a new No. 2 back door glass spacer.

HINT:

After removing the peeling paper, keep the exposed adhesive free from foreign matter.



c.

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

B537111C01
6.135,1.76 6.406,1.646 true 0.135,0.094 0.448,0.25 0.313,0.156 10 false *a 6.448,1.552 6.76,1.708 0.313,0.156 10 false *b
*a Backside *b Ceramic Notch


NOTICE:

Allow the primer to dry for 3 minutes or more.



Hide 64818B 6.INSTALL NO. 1 BACK DOOR GLASS SPACER

a.

Using a brush or sponge, apply the glass primer to the No. 1 back door glass spacer installation surface of the back door glass.

NOTICE:

Do not apply too much primer.



b.

Remove the peeling paper from a new No. 1 back door glass spacer.

HINT:

After removing the peeling paper, keep the exposed adhesive free from foreign matter.



c.

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

B537112C01
0.667,1.646 0.406,1.771 true 0.042,0.021 0.354,0.177 0.313,0.156 10 false *a 0.75,1.563 1.063,1.719 0.313,0.156 10 false *b
*a Backside *b Ceramic Notch


NOTICE:

Allow the primer to dry for 3 minutes or more.



Hide 64819B 7.INSTALL NO. 2 BACK WINDOW GLASS SPACER

a.

Using a brush or sponge, apply the glass primer to the No. 2 back window glass spacer installation surface of the back door glass.

NOTICE:

Do not apply too much primer.



b.

Remove the peeling paper from 2 new No. 2 back window glass spacers.

HINT:

After removing the peeling paper, keep the exposed adhesive free from foreign matter.



c.

Install the No. 2 back window glass spacer to the back door glass as shown in the illustration.

B537113C01
3.708,3.281 3.688,3.49 3.688,3.49 3.229,3.281 true 3.24,0.5 3.354,0.313 3.354,0.313 3.688,0.49 false 0.083,0.063 0.396,0.219 0.313,0.156 10 false *a 3.302,0.135 3.615,0.292 0.313,0.156 10 false *b 3.667,3.5 3.979,3.656 0.313,0.156 10 false *b 4.01,0.5 4.167,0.698 0.156,0.198 10 false a 4.01,3.135 4.167,3.333 0.156,0.198 10 false b
*a Backside *b Ceramic Notch


NOTICE:

Allow the primer to dry for 3 minutes or more.


Standard Dimension:
Area Dimension
a 11.7 mm (0.461 in.)
b 4.2 mm (0.165 in.)



Hide 75573C 8.INSTALL BACK WINDOW OUTSIDE MOULDING

a.

Using a brush or sponge, apply the glass primer to the back window outside moulding installation surface of the back door glass.

NOTICE:

Do not apply too much primer.



b.

Remove the peeling paper from 2 new back window outside mouldings.

HINT:

After removing the peeling paper, keep the exposed adhesive free from foreign matter.



c.

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

B537114C01
1.229,3.854 1.25,4.115 false 5.938,3.844 5.948,4.115 false 0.708,0.875 0.448,0.677 false 6.448,0.865 6.698,0.677 false 0.094,0.073 0.406,0.229 0.313,0.156 10 false *a 1.188,4.135 1.5,4.292 0.313,0.156 10 false *b 2.938,3.448 3.396,3.646 0.458,0.198 10 false A-A 1.688,2.271 1.948,2.49 0.26,0.219 10 false A 1.125,2.51 1.385,2.729 0.26,0.219 10 false A 0.271,0.969 0.427,1.167 0.156,0.198 10 false a 6.813,0.969 6.969,1.167 0.156,0.198 10 false a 5.906,4.167 6.219,4.323 0.313,0.156 10 false *b 0.26,0.531 0.563,0.698 0.302,0.167 10 false *b 6.781,0.542 7.094,0.698 0.313,0.156 10 false *b
*a Backside *b R End


NOTICE:

Allow the primer to dry for 3 minutes or more.


Standard Dimension:
Area Dimension
a 5.0 mm (0.197 in.)



Hide 68294A 9.INSTALL BACK DOOR GLASS ADHESIVE DAM

a.

Using a brush or sponge, apply the glass primer to the back door glass adhesive dam installation surface of the back door glass.

NOTICE:

Do not apply too much primer.



b.

Remove the peeling paper from 4 new back door glass adhesive dams.

HINT:

After removing the peeling paper, keep the exposed adhesive free from foreign matter.



c.

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

E468493C01
1.5,1.333 1.583,0.75 false 1.583,0.75 1.333,0.969 false 2.552,2.125 2.75,2.25 false 2.75,2.25 2.948,2.146 false 4.167,2.25 3.948,2.115 false 4.167,2.25 4.344,2.146 false 5.823,0.958 5.5,0.75 false 5.656,1.333 5.5,0.75 false 1.5,1.594 1.656,1.792 0.156,0.198 10 false a 3.26,1.979 3.417,2.177 0.156,0.198 10 false a 4.688,1.99 4.844,2.188 0.156,0.198 10 false a 5.604,1.594 5.76,1.792 0.156,0.198 10 false a 1.594,0.615 1.906,0.813 0.313,0.198 10 false *b 2.625,2.292 2.938,2.49 0.313,0.198 10 true *b 4.031,2.271 4.344,2.469 0.313,0.198 10 true *b 5.375,0.594 5.688,0.792 0.313,0.198 10 false *b 0.052,0.063 0.365,0.26 0.313,0.198 10 false *a
*a Backside *b Ceramic Notch


NOTICE:

Allow the primer to dry for 3 minutes or more.


Standard Dimension:
Area Dimension
a 7.2 mm (0.284 in.)



Hide 68131 10.INSTALL BACK DOOR GLASS

a.

Clean and shape the contact surface of the vehicle body.

i.
B514571C01
0.563,0.771 1.021,0.458 false 1.042,0.375 1.354,0.531 0.313,0.156 10 false *a 3.292,0.906 3.427,1.104 0.135,0.198 10 false a
*a Vehicle Body
V100155

Adhesive


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

Standard Dimension:
Area Dimension
a 1.0 mm (0.0394 in.) to 3.0 mm (0.118 in.)


NOTICE:

Be careful not to damage the vehicle body.


HINT:

Leave approximately 1.0 mm (0.0394 in.) to 3.0 mm (0.118 in.) of adhesive on the vehicle body.



ii.

Clean the contact surface of the vehicle body with a piece of cloth saturated with non-residue solvent.

HINT:

Even if all of the adhesive has been removed, clean the vehicle body.




b.

Position the back door glass.

i.

Using suction cups, place the back door glass in the correct position.


ii.

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

NOTICE:

w/ Window Defogger System:

Make sure that the wire harness of the window defogger is not caught between the body and back door glass.



iii.
B546082C01
1.74,0.479 2.083,0.375 2.083,0.375 1.719,0.76 true 0.542,1.417 0.813,1.344 true 0.594,0.792 0.865,0.844 true 2.542,1.396 2.813,1.448 true 2.479,0.865 2.771,0.792 true 2.135,0.25 2.448,0.448 0.313,0.198 10 false *a 0.885,0.76 1.094,0.958 0.208,0.198 10 true *1 0.875,1.24 1.083,1.438 0.208,0.198 10 true *3 2.229,0.771 2.438,0.969 0.208,0.198 10 true *2 2.323,1.281 2.531,1.479 0.208,0.198 10 true *4
*1 Back Window Glass Clip LH
*2 Back Window Glass Clip RH
*3 No. 2 Back Door Glass Spacer
*4 No. 1 Back Door Glass Spacer
*a Matchmarks


When using a new back door glass:

Place matchmarks on the back door glass and vehicle body at the locations indicated in the illustration.

NOTICE:

Check that the back window glass clip LH, back window glass clip RH, No. 1 back door glass spacer and No. 2 back door glass spacer are attached to the back door panel correctly.


HINT:

When reusing a back door glass, check the position of the matchmarks and make adjustments.



iv.

Using suction cups, remove the back door glass.


v.

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

NOTICE:
·

Do not apply too much primer.

·

Do not apply primer to the adhesive.

·

When applying the primer, take care of the seams of the panel and spot welds.




vi.

Using a brush or sponge, apply the glass primer as shown in the illustration.

E463807C01
0.063,0.073 0.375,0.271 0.313,0.198 10 false *a 3.438,0.063 3.594,0.26 0.156,0.198 10 false A 3.469,0.729 3.625,0.927 0.156,0.198 10 false A 2.531,0.083 2.688,0.281 0.156,0.198 10 false B 2.531,0.74 2.708,0.958 0.177,0.219 10 false B 3.438,1.979 3.594,2.177 0.156,0.198 10 false D 1.073,1.083 1.229,1.281 0.156,0.198 10 false C 1.781,1.188 1.938,1.385 0.156,0.198 10 false C 3.448,1.365 3.604,1.563 0.156,0.198 10 false D 0.813,2.302 1.271,2.5 0.458,0.198 10 false A-A 4.99,2.25 5.448,2.448 0.458,0.198 10 false C-C 0.552,3.406 1.01,3.604 0.458,0.198 10 false D-D 2,2.302 2.188,2.521 0.188,0.219 10 false a 2.292,2.302 2.448,2.5 0.156,0.198 10 false c 5.719,2.344 5.875,2.542 0.156,0.198 10 false b 2.531,1.323 2.708,1.542 0.177,0.219 10 false F 2.51,2 2.688,2.219 0.177,0.219 10 false F 5.094,1.198 5.25,1.396 0.156,0.198 10 false E 5.708,1.115 5.865,1.313 0.156,0.198 10 false E 3.094,3.469 3.552,3.667 0.458,0.198 10 false E-E 1.313,3.5 1.469,3.698 0.156,0.198 10 false a 4.083,3.5 4.24,3.698 0.156,0.198 10 false a 4.063,2.313 4.24,2.5 0.177,0.188 10 false a 4.375,2.323 4.531,2.521 0.156,0.198 10 false c 5.302,2.333 5.458,2.531 0.156,0.198 10 false c 1.01,3.5 1.167,3.698 0.156,0.198 10 false c 4.396,3.5 4.552,3.698 0.156,0.198 10 false c 2.979,2.292 3.438,2.49 0.458,0.198 10 false B-B 4.917,3.469 5.375,3.667 0.458,0.198 10 false F-F 5.552,3.479 5.708,3.677 0.156,0.198 10 false a 5.26,3.49 5.417,3.688 0.156,0.198 10 false c
*a Backside - -
V100155

Glass Primer - -


NOTICE:

Do not apply too much primer.


Standard Dimension:
Area Dimension
a 14 mm (0.551 in.)
b 22 mm (0.866 in.)
c 6.0 mm (0.236 in.)



vii.
B214800C84
1.354,0.583 1.177,0.479 false 2.917,0.375 2.521,0.542 true 0.583,0.667 0.74,0.854 0.156,0.188 10 false a 1.271,1.448 1.417,1.635 0.146,0.188 10 false a 1.125,0.865 1.25,1.063 0.125,0.198 10 false b 0.771,1.031 0.917,1.177 0.146,0.146 10 false b 1.406,0.531 1.604,0.698 0.198,0.167 10 false *b 2.979,0.302 3.177,0.469 0.198,0.167 10 false *a
*a Sealer Gun
*b Nozzle
V100155

Adhesive


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

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



viii.

Load the sealer gun with the cartridge.


ix.

Apply adhesive to the glass as shown in the illustration.

Adhesive:

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


E463808C01
1.656,2.938 2.135,3.188 true 4.063,2.948 4.542,3.198 true 5.896,2.958 6.365,3.208 6.365,3.208 6.167,2.958 true 1.104,4.115 1.583,4.365 true 3.906,4.115 4.385,4.365 true 4.604,1.719 4.719,1.969 true 4.438,1.708 4.313,1.958 true 5.823,4.125 6.302,4.375 true 0.063,0.073 0.375,0.271 0.313,0.198 10 false *a 3.417,0.115 3.573,0.313 0.156,0.198 10 false A 3.427,0.708 3.583,0.906 0.156,0.198 10 false A 2.531,0.125 2.688,0.323 0.156,0.198 10 false B 2.542,0.698 2.719,0.917 0.177,0.219 10 false B 3.438,1.969 3.594,2.167 0.156,0.198 10 false D 1.135,1.104 1.292,1.302 0.156,0.198 10 false C 1.76,1.167 1.917,1.365 0.156,0.198 10 false C 3.438,1.354 3.594,1.552 0.156,0.198 10 false D 0.49,2.24 0.948,2.438 0.458,0.198 10 false A-A 2.885,2.25 3.344,2.448 0.458,0.198 10 false B-B 5.177,1.938 5.635,2.135 0.458,0.198 10 false C-C 0.292,3.281 0.75,3.479 0.458,0.198 10 false D-D 1.823,2.167 1.979,2.365 0.156,0.198 10 false a 2.188,3.115 2.344,3.313 0.156,0.198 10 false *b 5.969,2.219 6.125,2.417 0.156,0.198 10 false b 2.531,1.365 2.708,1.583 0.177,0.219 10 false F 2.542,1.958 2.719,2.177 0.177,0.219 10 false F 5.063,1.167 5.219,1.365 0.156,0.198 10 false E 5.698,1.083 5.854,1.281 0.156,0.198 10 false E 2.844,3.302 3.302,3.5 0.458,0.198 10 false E-E 4.073,3.385 4.229,3.583 0.156,0.198 10 false a 4.208,2.188 4.365,2.385 0.156,0.198 10 false a 5.76,2.031 5.917,2.229 0.156,0.198 10 false c 0.833,3.375 0.99,3.573 0.156,0.198 10 false a 5.625,2.219 5.781,2.417 0.156,0.198 10 false a 4.542,3.094 4.698,3.292 0.156,0.198 10 false *b 4.427,4.302 4.583,4.5 0.156,0.198 10 false *b 1.615,4.313 1.771,4.51 0.156,0.198 10 false *b 6.406,3.167 6.563,3.365 0.156,0.198 10 false *b 4.698,2.01 4.854,2.208 0.156,0.198 10 false *c 4.208,2 4.365,2.198 0.156,0.198 10 false *b 5.104,3.281 5.563,3.479 0.458,0.198 10 false F-F 5.563,3.385 5.719,3.583 0.156,0.198 10 false a 6.344,4.365 6.5,4.563 0.156,0.198 10 false *b
*a Backside *b Adhesive Positioning Center
*c Ceramic Notch - -
V100155

Adhesive - -


NOTICE:

Allow the primer to dry for 3 minutes or more.


Standard Dimension:
Area Dimension
a 13 mm (0.512 in.)
b 8.0 mm (0.315 in.)
c 21 mm (0.827 in.)




c.
B537107C01
1.74,0.479 2.083,0.375 2.083,0.375 1.719,0.76 true 2.135,0.25 2.448,0.448 0.313,0.198 10 false *a
*a Matchmarks


Install the back door glass to the vehicle body.

i.

Using suction cups, position the back door glass so that the matchmarks are aligned.

NOTICE:
·

Check that the back window glass clip LH, back window glass clip RH, No. 1 back door glass spacer and No. 2 back door glass spacer are attached to the back door panel correctly.

·

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




ii.

Press it in gently along the rim.

HINT:

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



iii.

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

NOTICE:

Apply adhesive up to the edge of the back door glass.



iv.

Hold the back door glass using protective tape until the applied adhesive becomes hard.

NOTICE:

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) 1 hour and 30 minutes
20°C (68°F) 5 hours
5°C (41°F) 24 hours




d.
B544248

Connect the connector.


Hide 82186 11.INSTALL NO. 1 REAR WINDOW WIRE

a.
B544249C01
0,0 0,0 false
V100135

Wire Harness Connector
V100136

Bolt


Attach the clamp and install the No. 1 rear window wire.


b.

Install the bolt.

Torque:
10 N*m (102 kgf*cm, 7 ft.*lbf)


c.

Connect the wire harness connector.


Hide 67937B 22.INSTALL BACK DOOR SIDE GARNISH RH

HINT:

Use the same procedure described for the LH side.


Hide 24. CHECK FOR LEAK AND REPAIR

a.

Conduct a leak test after the adhesive has completely hardened.


b.

Seal any leaks with auto glass sealer.


c.

Remove the protective tape and matchmark.