BACK DOOR GLASS (for Hatchback): Installation

1. Using a scraper, remove the clips, dam and adhesive sticking to the back door glass.
2. Clean the outer circumference of the back door glass with a non-residue solvent.
   NOTE:

   • 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.
   Fig 1: Removing Clips, Dam And Adhesive Sticking From Back Door Glass

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   HINT:

   Since the pin is for positioning the glass, there is no need to replace it with a new one when reusing the glass, even if damaged.

1. Clean and shape the contact surface of the vehicle body.
   1. Using a knife, cut away any rough adhesive on the contact surface of the vehicle body to ensure the appropriate surface shape.
      NOTE: Do not damage the vehicle body.

      HINT:

      Leave as much adhesive on the vehicle body as possible.

      Fig 2: Identifying Adhesive On Contact Surface Of Vehicle Body

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Clean the contact surface of the vehicle body with a shop rag or piece of cloth saturated with cleaner.

      HINT:

      Clean the vehicle body even if all the adhesive has been removed.

1. Apply Primer G to the glass where the dams will be installed.
   NOTE:

   • Allow the primer to dry for 3 minutes or more.
   • Throw away any leftover Primer G.
   • Do not apply too much Primer G.
2. Install 2 new back door glass adhesive dams as shown in the illustration.

   Specification 

   BACK WINDOW GLASS ADHESIVE DAM SPECIFICATION
   
   

   Area	Measurement
   a	4.2 mm (0.165 In.)

   Fig 3: Installing Back Door Glass Adhesive Dams

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Position the back door glass.
   1. Using suction cups, place the back door glass in the correct position.
   2. Check that the whole contact surface of the back door glass rim is perfectly even.
   3. Place matchmarks on the back door glass and vehicle body.
      NOTE: Check that the stoppers are attached to the vehicle body correctly.

      HINT:

      When reusing the back door glass, check and correct the matchmark positions.

   4. Using suction cups, remove the back door glass.
      Fig 4: Placing Matchmarks On Back Door Glass And Vehicle Body

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a brush, 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 M to the adhesive.
   • Throw away any leftover Primer M.
   • Do not apply too much Primer M.
   Fig 5: Applying Primer M To Exposed Part Of Vehicle Body

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a brush or sponge, apply Primer G to the edge of the back door glass and contact surface.
   Fig 6: Installing Back Door Glass

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE:

   • Allow the primer to dry for 3 minutes or more.
   • Throw away any leftover Primer G.
   • Do not apply too much Primer G.

   HINT:

   If Primer G is applied to any areas other than those specified, wipe off the primer with a clean shop rag or piece of cloth before it dries.

   Specification 

   BACK DOOR GLASS SPECIFICATION
   
   

   Area	Measurement
   a	6.9 mm (0.272 In.)
   b	11.0 mm (0.433 In.)
   c	26.7 mm (1.051 In.)
   d	40.7 mm (1.602 In.)

4. Apply adhesive.

   Adhesive: 

   Part No. 08850-00801 or the equivalent 

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

      HINT:

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

      Usage time frame 

      BACK DOOR GLASS TEMPERATURE AND USAGE TIME FRAME REFERENCE
      
      

      Temperature	Usage Time Frame
      35°C (95°F)	15 minutes
      20°C (68°F)	1 hour 40 minutes
      5°C (41 °F)	8 hours

      Fig 7: Identifying Cutting Dimension Of Cartridge Nozzle Tip

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Load the sealer gun with the cartridge.
   3. Apply adhesive to the back door glass, as shown in the illustration.
      Fig 8: Identifying Adhesive Applying Area Of Back Door Glass

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Specification 

      BACK DOOR GLASS SPECIFICATION
      
      

      Area	Measurement
      a	12.0 mm (0.472 in.)
      b	8.0 mm (0.315 in.)
      c	13.5 mm (0.532 In.)
      d	33.7 mm (1.327 in.)

5. Install the back door glass onto the vehicle body.
   1. Using suction cups, position the back door glass so that the matchmarks are aligned. Press it in gently along the rim.
      NOTE:

      • Allow the primer to dry for 3 minutes or more.
      • Check that the stoppers are attached to the vehicle body correctly.
      • Check that the vehicle body and back door glass have a small gap between them.
   2. Gently press the front surface of the back door glass to ensure that the back door glass is securely fitted to the vehicle body.
      Fig 9: Placing Matchmarks On Back Door Glass And Vehicle Body

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. Using a scraper, remove any excessive or protruding adhesive.

      HINT:

      Apply adhesive onto the back door glass rim.

      NOTE: Do not to drive the vehicle within the time indicated in the table below.
      Minimum time
      BACK DOOR GLASS TEMPERATURE AND TIMING REFERENCE
      
      

      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

      Fig 10: Removing Excessive Or Protruding Adhesive

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Conduct a leak test after the adhesive has completely hardened.
2. Seal any leakage with auto glass sealer.

Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)