RM36D0EC _59 Vehicle Exterior _083107 WINDOW / GLASS _0400967 BACK DOOR GLASS A

WINDOW / GLASS  BACK DOOR GLASS  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, 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 64819C 2.INSTALL NO. 2 BACK WINDOW GLASS SPACER

a.

Using a brush or sponge, coat 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 a new No. 2 back window glass spacer.

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.

B526642
6.49,0.719 6.594,1.031 true 0.135,0.094 0.448,0.25 0.313,0.156 10 false *a 6.604,1.094 6.917,1.25 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 3.INSTALL NO. 1 BACK DOOR GLASS SPACER

a.

Using a brush or sponge, coat the glass primer to the No. 1 back window 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 window glass spacer.

HINT:

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



c.

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

B526641
0.615,0.656 0.438,0.927 true 0.042,0.021 0.354,0.177 0.313,0.156 10 false *a 0.333,0.917 0.646,1.073 0.313,0.156 10 false *b
*a Backside *b Ceramic Notch


NOTICE:

Allow the primer to dry for 3 minutes or more.



Hide 62785F 4.INSTALL BACK DOOR GLASS SPACER

a.

Using a brush or sponge, coat the glass primer to the back door glass spacer installation surface of the back door glass.

NOTICE:

Do not apply too much primer.



b.

Remove the peeling paper from 2 new back door glass spacers.

HINT:

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



c.

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

B526644
4.563,0.885 4.448,0.99 true 2.594,0.885 2.698,0.99 false 0.083,0.063 0.396,0.219 0.313,0.156 10 false *a 4.292,0.958 4.604,1.115 0.313,0.156 10 false *b 2.76,0.969 3.073,1.125 0.313,0.156 10 false *b
*a Backside *b Ceramic Notch


NOTICE:

Allow the primer to dry for 3 minutes or more.



Hide 75575D 5.INSTALL BACK WINDOW LOWER MOULDING

a.

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

NOTICE:

Do not apply too much primer.



b.

Remove the peeling paper from a new back window lower moulding.

HINT:

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



c.

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

B529414
5.958,3.99 6.375,3.927 false 1.198,3.99 0.781,3.917 false 0.094,0.115 0.406,0.271 0.313,0.156 10 false *a 0.604,3.813 0.917,3.969 0.313,0.156 10 false *b 6.427,3.865 6.74,4.021 0.313,0.156 10 false *b 2.792,4.438 2.948,4.635 0.156,0.198 10 false a 3.375,2.5 3.531,2.698 0.156,0.198 10 false A 3.406,3.052 3.563,3.25 0.156,0.198 10 false A 2.969,3.521 3.427,3.719 0.458,0.198 10 false A-A 1.417,3.406 1.573,3.604 0.156,0.198 10 false b 5.635,3.385 5.792,3.583 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 8.8 mm (0.347 in.)
b -3.0 mm (-0.118 in.) to 3.0 mm (0.118 in.)



Hide 68294B 6.INSTALL BACK DOOR GLASS ADHESIVE DAM

a.

Using a brush or sponge, coat 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 6 new back door glass adhesive dam.

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.

B526643
1.656,3.042 1.552,2.844 false 1.052,3.188 1.167,3.354 false 6.052,3.188 5.885,3.375 false 5.448,3.052 5.646,2.844 false 0.146,0.094 0.458,0.25 0.313,0.156 10 false *a 1.177,3.385 1.49,3.542 0.313,0.156 10 false *b 5.677,2.708 5.99,2.865 0.313,0.156 10 false *b 1.375,2.708 1.688,2.865 0.313,0.156 10 false *b 5.771,3.365 6.083,3.521 0.313,0.156 10 false *b
*a Backside *b Ceramic Notch


NOTICE:

Allow the primer to dry for 3 minutes or more.



Hide 68131 7.INSTALL BACK DOOR GLASS

a.

Clean and shape the contact surface of the vehicle body.

i.
B514571
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 (0.039 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:

Make sure that the wire harness of the No. 6 antenna cord sub-assembly is not caught between the body and back door glass.



iii.
B526638
1.76,0.385 2.177,0.188 2.177,0.188 1.781,0.698 true 2.219,0.104 2.531,0.302 0.313,0.198 10 false *a
*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 No. 2 back door glass spacer and No. 1 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, coat 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, coat the glass primer as shown in the illustration.

B526645
0.063,0.073 0.375,0.271 0.313,0.198 10 false *a 2.563,1.177 2.719,1.375 0.156,0.198 10 false A 2.552,1.865 2.708,2.063 0.156,0.198 10 false A 2,1.219 2.156,1.417 0.156,0.198 10 false B 2.01,1.854 2.167,2.052 0.156,0.198 10 false B 2.521,2.865 2.677,3.063 0.156,0.198 10 false D 0.115,2.417 0.271,2.615 0.156,0.198 10 false C 0.813,2.479 0.969,2.677 0.156,0.198 10 false C 2.531,3.563 2.688,3.76 0.156,0.198 10 false D 5.479,0.125 5.938,0.323 0.458,0.198 10 false A-A 5.5,1.375 5.958,1.573 0.458,0.198 10 false B-B 5.208,2.333 5.667,2.531 0.458,0.198 10 false C-C 4.667,3.438 5.125,3.635 0.458,0.198 10 false D-D 6.625,0.219 6.781,0.417 0.156,0.198 10 false a 6.146,0.24 6.302,0.438 0.156,0.198 10 false b 6.49,2.448 6.646,2.646 0.156,0.198 10 false c 5.802,2.438 5.958,2.635 0.156,0.198 10 false d 6.615,1.313 6.771,1.51 0.156,0.198 10 false a 6.135,1.302 6.292,1.5 0.156,0.198 10 false b 6,3.552 6.156,3.75 0.156,0.198 10 false e 5.094,3.552 5.25,3.75 0.156,0.198 10 false b
*a Backside - -
V100155

Glass Primer - -


NOTICE:

Do not apply too much primer.


Standard Dimension:
Area Dimension
a 6.7 mm (0.264 in.)
b 14 mm (0.551 in.)
c 66.2 mm (2.61 in.)
d 22 mm (0.866 in.)
e 31.6 mm (1.24 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


B526646
3.021,3.802 3.271,3.198 true 5.104,4.281 4.906,4.573 true 5.948,3.219 5.458,3.552 5.458,3.552 5.688,3.219 true 6.198,1.865 5.958,2.094 true 6.198,0.823 6.042,1.052 true 3.646,1.573 4.552,0.917 4.552,0.917 4.292,1.5 false 0.073,0.083 0.385,0.281 0.313,0.198 10 false *a 2.5,1.188 2.656,1.385 0.156,0.198 10 false A 2.552,1.896 2.708,2.094 0.156,0.198 10 false A 2.031,1.208 2.188,1.406 0.156,0.198 10 false B 0.083,2.406 0.24,2.604 0.156,0.198 10 false C 2.51,3.573 2.667,3.771 0.156,0.198 10 false D 5.49,0.26 5.823,0.458 0.333,0.198 10 false A-A 2.031,1.865 2.188,2.063 0.156,0.198 10 false B 0.802,2.531 0.958,2.729 0.156,0.198 10 false C 2.427,2.927 2.583,3.125 0.156,0.198 10 false D 5.542,1.208 5.875,1.406 0.333,0.198 10 false B-B 5.073,2.281 5.406,2.479 0.333,0.198 10 false C-C 4.5,3.385 4.833,3.583 0.333,0.198 10 false D-D 6.458,0.104 6.615,0.302 0.156,0.198 10 false a 6.49,1.156 6.646,1.354 0.156,0.198 10 false a 6.323,2.469 6.479,2.667 0.156,0.198 10 false b 6.156,2.177 6.313,2.375 0.156,0.198 10 false c 5.917,3.563 6.073,3.76 0.156,0.198 10 false d 5.792,2.448 5.948,2.646 0.156,0.198 10 false e 2.917,3.823 3.229,4.021 0.313,0.198 10 false *b 4.552,0.75 4.865,0.948 0.313,0.198 10 false *c 4.729,4.594 5.042,4.792 0.313,0.198 10 false *b 5.292,3.542 5.604,3.74 0.313,0.198 10 false *b 5.792,2.063 6.104,2.26 0.313,0.198 10 false *b 5.917,1.052 6.229,1.25 0.313,0.198 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 13.7 mm (0.539 in.)
b 73.1 mm (2.88 in.)
c 81.1 mm (3.19 in.)
d 38.6 mm (1.52 in.)
e 8.0 mm (0.315 in.)




c.
B526638
1.76,0.385 2.177,0.188 2.177,0.188 1.781,0.698 true 2.219,0.104 2.531,0.302 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 No. 1 back door glass spacer and the 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 a 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.

Connect the 2 connectors.

B538367


Hide 10.INSTALL REAR LIGHT ASSEMBLY RH

HINT:

Use the same procedure described for the LH side.


Hide 13. 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.