Back Door Glass (For Double Swing Out Type) Installation

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

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

NOTICE:

1. Do not touch the glass surface after cleaning it.
   
2. Be careful not to damage the glass.
   
3. Even if using new glass, clean the glass with non-residue solvent.
   

Apply Primer G to the back door glass LH where the clips will be installed.

NOTICE:

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

HINT:

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.

Remove the peeling paper from 2 new clips.

Install the 2 back window glass clips to the back door glass LH at the locations shown in the illustration.

Apply Primer G to the back door glass LH where the clips will be installed.

NOTICE:

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

HINT:

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.

Remove the peeling paper from 2 new clips.

Install the 2 back window glass clips to the back door glass LH at the locations shown in the illustration.

Apply Primer G to the back door glass LH where the dams will be installed.

NOTICE:

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

HINT:

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.

Remove the peeling paper from 2 new dams.

Install the 2 No. 1 back door glass adhesive dams to the back door glass LH at the locations shown in the illustration.

Apply Primer G to the back door glass LH where the back window outside moulding will be installed.

NOTICE:

1. Allow the primer to dry for 3 minutes or more.
   
2. Throw away any leftover primer.
   
3. Do not apply too much primer.
   
4. Do not apply primer outside the ceramic area.
   

HINT:

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.

Standard:

Area	Specified Condition
a	10.1 mm (0.398 in.)
b	3.0 mm (0.118 in.)

Remove the peeling paper from a new moulding.

Install the back window outside moulding to the back door glass LH at the location shown in the illustration.

Standard:

Area	Specified Condition
a	10.1 mm (0.398 in.)
b	6.1 mm (0.240 in.)
c	4.6 mm (0.181 in.)

Apply Primer G to the back door glass LH where the back door glass adhesive dam will be installed.

NOTICE:

1. Allow the primer to dry for 3 minutes or more.
   
2. Throw away any leftover primer.
   
3. Do not apply too much primer.
   
4. Do not apply primer outside the ceramic area.
   

HINT:

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.

Standard:

Area	Specified Condition
a	11.0 mm (0.433 in.)
b	3.0 mm (0.118 in.)

Remove the peeling paper from a new dam.

Install the back door glass adhesive dam to the back door glass LH at the location shown in the illustration.

Standard:

Area	Specified Condition
a	5.8 mm (0.228 in.)
b	7.0 mm (0.276 in.)
c	6.8 mm (0.268 in.)

Position the glass.

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

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

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

   HINT:

   1. Placing matchmarks is only necessary when installing new back door glass. When reinstalling the used back door glass, matchmarks should already be present.
      
   2. When reusing the glass, check and correct the matchmark positions.
      

   NOTICE:

   Check that the stoppers are attached to the back door correctly.

4. Using suction cups, remove the back door glass.
   

   Text in Illustration

   *1

   Matchmark

Using a brush or sponge, apply Primer M to the exposed part of the back door.

NOTICE:

1. Allow the primer to dry for 3 minutes or more.
   
2. Do not apply primer to the adhesive.
   
3. Throw away any leftover primer.
   
4. Do not apply too much primer.
   

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

Standard:

Area	Specified Condition
a	15.3 mm (0.602 in.)
b	3.0 mm (0.118 in.)
c	20.0 mm (0.787 in.)
d	17.0 mm (0.669 in.)
e	29.0 mm (1.14 in.)
f	37.0 mm (1.46 in.)

HINT:

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

NOTICE:

1. Allow the primer to dry for 3 minutes or more.
   
2. Throw away any leftover primer.
   
3. Do not apply too much primer.
   
4. Do not apply primer outside the ceramic area.
   

Apply adhesive to the back door glass LH.

Adhesive:

Toyota Genuine Windshield Glass Adhesive or equivalent

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

   HINT:

   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 LH as shown in the illustration.
   
   

   
   
   
   
   

   Text in Illustration

   *1	Adhesive	*2	Adhesive Center Line
   *3	Ceramic Notch	-	-
   *a	Backside	-	-

   Standard:

   Area	Specified Condition
   a	12.0 mm (0.472 in.)
   b	8.0 mm (0.315 in.)
   c	11.3 mm (0.445 in.)
   d	16.0 mm (0.630 in.)
   e	13.0 mm (0.512 in.)
   f	25.0 mm (0.984 in.)

Install the back door glass LH to the vehicle body.

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

   NOTICE:

   1. Allow the primer coating to dry for 3 minutes or more.
      
   2. Check that the clips are attached to the vehicle body correctly.
      
   3. Check the clearance between the vehicle body and glass.
      

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





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

   HINT:

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

   NOTICE:

   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

   Text in Illustration

   *1

   Adhesive

4. Connect the connectors.
   

Apply Primer G to the back door glass RH where the clips will be installed.

NOTICE:

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

HINT:

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.

Remove the peeling paper from 2 new clips.

Install the 2 back window glass clips to the back door glass RH at the locations shown in the illustration.

Apply Primer G to the back door glass RH where the clips will be installed.

NOTICE:

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

HINT:

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.

Remove the peeling paper from 2 new clips.

Install the 2 back window glass clips to the back door glass RH at the locations shown in the illustration.

Apply Primer G to the back door glass RH where the dams will be installed.

NOTICE:

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

HINT:

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.

Remove the peeling paper from 3 new dams.

Install the 3 No. 1 back door glass adhesive dams to the back door glass RH at the locations shown in the illustration.

Apply Primer G to the back door glass RH where the back window outside moulding will be installed.

NOTICE:

1. Allow the primer to dry for 3 minutes or more.
   
2. Throw away any leftover primer.
   
3. Do not apply too much primer.
   
4. Do not apply primer outside the ceramic area.
   

HINT:

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.

Standard:

Area	Specified Condition
a	10.1 mm (0.398 in.)
b	3.0 mm (0.118 in.)

Remove the peeling paper from a new moulding.

Install the back window outside moulding to the back door glass RH at the location shown in the illustration.

Standard:

Area	Specified Condition
a	10.1 mm (0.398 in.)
b	5.7 mm (0.224 in.)
c	4.6 mm (0.181 in.)

Apply Primer G to the back door glass RH where the back window outside moulding will be installed.

NOTICE:

1. Allow the primer to dry for 3 minutes or more.
   
2. Throw away any leftover primer.
   
3. Do not apply too much primer.
   
4. Do not apply primer outside the ceramic area.
   

HINT:

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.

Standard:

Area	Specified Condition
a	11.0 mm (0.433 in.)
b	3.0 mm (0.118 in.)

Remove the peeling paper from a new moulding.

Install the back window outside moulding to the back door glass RH at the location shown in the illustration.

Standard:

Area	Specified Condition
a	2.8 mm (0.110 in.)
b	6.8 mm (0.268 in.)

Position the glass.

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

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

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

   HINT:

   1. Placing matchmarks is only necessary when installing new back door glass. When reinstalling the used back door glass, matchmarks should already be present.
      
   2. When reusing the glass, check and correct the matchmark positions.
      

   NOTICE:

   Check that the stoppers are attached to the back door correctly.

4. Using suction cups, remove the back door glass.
   

   Text in Illustration

   *1

   Matchmark

Using a brush or sponge, apply Primer M to the exposed part of the back door.

NOTICE:

1. Allow the primer to dry for 3 minutes or more.
   
2. Do not apply primer to the adhesive.
   
3. Throw away any leftover primer.
   
4. Do not apply too much primer.
   

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

Standard:

Area	Specified Condition
a	3.0 mm (0.118 in.)
b	37.0 mm (1.46 in.)
c	29.0 mm (1.14 in.)
d	17.0 mm (0.670 in.)
e	20.0 mm (0.787 in.)

HINT:

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

NOTICE:

1. Allow the primer to dry for 3 minutes or more.
   
2. Throw away any leftover primer.
   
3. Do not apply too much primer.
   
4. Do not apply primer outside the ceramic area.
   

Apply adhesive to the back door glass RH.

Adhesive:

Toyota Genuine Windshield Glass Adhesive or equivalent

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

   HINT:

   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 RH as shown in the illustration.
   
   

   
   
   
   
   

   Text in Illustration

   *1	Adhesive	*2	Adhesive Center Line
   *3	Ceramic Notch	-	-
   *a	Backside	-	-

   Standard:

   Area	Specified Condition
   a	12.0 mm (0.472 in.)
   b	8.0 mm (0.315 in.)
   c	11.3 mm (0.445 in.)
   d	25.0 mm (0.984 in.)
   e	13.0 mm (0.512 in.)

Install the back door glass RH to the vehicle body.

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

   NOTICE:

   1. Allow the primer coating to dry for 3 minutes or more.
      
   2. Check that the clips are attached to the vehicle body correctly.
      
   3. Check the clearance between the vehicle body and glass.
      

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





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

   HINT:

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

   NOTICE:

   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

   Text in Illustration

   *1

   Adhesive

4. Connect the connectors.
   

Conduct a leak test after the adhesive has completely hardened.

Seal any leaks with auto glass sealer.

Attach the 10 clips to install the back door trim panel.

Connect the 2 links to the back door inside handle.

Attach the guide in the direction indicated by the arrow in the illustration to install the back door inside handle.

Install the screw.

Install the assist grip with the 2 bolts.

Attach the 2 claws to close the 2 covers.

Clean the back door panel surface.

1. Using a heat light, heat the back door panel surface.
   

2. Remove the double-sided tape from the back door panel surface.
   

3. Wipe off any tape adhesive residue with cleaner.
   

Install a new back door center weatherstrip.

1. Remove the peeling paper from the face of the back door center weatherstrip.
   

   HINT:

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

2. Attach the 5 clips to install the back door center weatherstrip.
   

   HINT:

   Press the back door center weatherstrip firmly to install it.

Clean the wiper arm serrations.

Clean the wiper pivot serrations with a wire brush.

Operate the rear wiper, and stop the rear wiper motor at the automatic stop position.

Align the tips of the blade with the marks as shown in the illustration.

Install the rear wiper arm and blade assembly with the nut.

Torque:

5.5 N*m{56 kgf*cm, 49 in.*lbf}

Close the wiper arm head cap.

Attach the 13 clips to install the back door trim panel.

Attach the 2 claws and clamp.

Attach the 5 clips and 2 claws to install the back door trim cover.

Install the assist grip with the 2 bolts.

Attach the 2 claws to close the 2 covers.

Clean the threaded surfaces on the vehicle body with a non-residue solvent.

Apply adhesive to the threads of bolt A and B.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

Install the spare wheel carrier with the 9 bolts.

Torque:

Bolt A:

29 N*m{196 kgf*cm, 21 ft.*lbf}

Bolt B:

15 N*m{148 kgf*cm, 11 ft.*lbf}

Install the spare tire with the 3 bolts.

Torque:

90 N*m{918 kgf*cm, 66 ft.*lbf}

Attach the clip to install the spare wheel cover.

Install the 2 nuts.

Attach the 2 claws to install the spare wheel carrier hinge bracket.