Back Window Glass: Service and Repair

Back Window Assy:

REPLACEMENT

1. REMOVE REAR SEAT BACK HINGE COVER (DOUBLE CAB)
2. REMOVE REAR SEAT BACK ASSEMBLY LH (DOUBLE CAB)
3. REMOVE REAR SEAT BACK ASSEMBLY RH (DOUBLE CAB)
4. REMOVE REAR SEAT BACK HINGE SUB-ASSEMBLY LH (DOUBLE CAB)
5. REMOVE REAR SEAT BACK HINGE SUB-ASSEMBLY RH (DOUBLE CAB)
6. REMOVE FRONT DOOR SCUFF PLATE LH (EXCEPT DOUBLE CAB)
7. REMOVE FRONT DOOR SCUFF PLATE RH (EXCEPT DOUBLE CAB)

HINT: Follow the same procedures as for the front door scuff plate LH.

8. REMOVE REAR DOOR SCUFF PLATE LH (EXCEPT REGULAR CAB)
9. REMOVE REAR DOOR SCUFF PLATE RH (EXCEPT REGULAR CAB)

HINT: Follow the same procedures as for the rear door scuff plate LH.

10. REMOVE ROOF SIDE INNER GARNISH CAP LH (ACCESS CAB)
11. REMOVE ROOF SIDE INNER GARNISH CAP RH (ACCESS CAB)

HINT: Follow the same procedures as for the roof side inner garnish LH.

12. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP LH (EXCEPT DOUBLE CAB)

13. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP RH (EXCEPT DOUBLE CAB)

HINT: Follow the same procedures as for the front door opening trim weatherstrip LH.

14. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH (DOUBLE CAB)
15. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP RH (DOUBLE CAB)

HINT: Follow the same procedures as for the rear door opening trim weatherstrip LH.

16. REMOVE BACK PANEL TRIM COVER (EXCEPT DOUBLE CAB)

17. REMOVE BACK PANEL TRIM COVER (REGULAR CAB (BENCH SEAT TYPE))
18. REMOVE BACK PANEL GARNISH UPPER (REGULAR CAB)
19. REMOVE JACK ASSEMBLY (REGULAR CAB (SEPARATE SEAT TYPE))
20. REMOVE BACK PANEL TRIM COVER (REGULAR CAB (SEPARATE SEAT TYPE))
21. REMOVE BACK PANEL TRIM (ACCESS CAB, REGULAR CAB (SEPARATE SEAT TYPE))
22. REMOVE LUGGAGE COMPARTMENT SIDE TRAY (DOUBLE CAB)
23. REMOVE REAR SEAT BACK HINGE SUB-ASSEMBLY CENTER (DOUBLE CAB)
24. REMOVE LUGGAGE COMPARTMENT SIDE TRAY (DOUBLE CAB)
25. REMOVE QUARTER TRIM PANEL LOWER LH
26. REMOVE QUARTER TRIM PANEL LOWER RH

HINT: Follow the same procedures as for the quarter trim panel lower LH.

27. REMOVE ROOF SIDE GARNISH INNER LH (ACCESS CAB)
28. REMOVE ROOF SIDE GARNISH INNER RH (ACCESS CAB)

HINT: Follow the same procedures as for the roof side garnish inner LH.

29. REMOVE QUARTER INSIDE TRIM BOARD LH

30. REMOVE QUARTER INSIDE TRIM BOARD RH

HINT: Follow the same procedures as for the quarter inside trim board LH.

31. REMOVE COAT HOOK

32. REMOVE BACK WINDOW ASSEMBLY
a. Remove the 2 nuts.

b. Apply protective tape to the outer circumference of the back window, as shown in the illustration.
c. From the interior, insert piano wires between the vehicle body and back window, as shown in the illustration.
d. Tie objects that can serve as handles (for example, wooden blocks) to all wire ends.

NOTE: When separating the back window from the vehicle, be careful not to damage the vehicle's paint or exterior/interior ornaments.

e. Cut through the adhesive by pulling the piano wire around the back window.

f. Disengage the 2 clips.
g. Using suction cups, remove the back window.

NOTE: Leave as much adhesive on the vehicle body as possible when removing the back window.

33. CLEAN VEHICLE BODY
a. 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: Be careful not to damage the vehicle body.

HINT: Leave as much adhesive on the vehicle body as possible.

2. Clean the contact surface of the vehicle body with a shop rag saturated with cleaner.

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

34. INSTALL BACK WINDOW ASSEMBLY
a. Position the windshield glass.
1. Using suction cups, place the back window in the correct position.
2. Check that the whole contact surface of the back window rim is perfectly even.
3. Place matchmarks over the back window and vehicle body.

NOTE: Check that the stoppers are attached to the vehicle body correctly.

HINT: When reusing the back window, check and correct the match mark positions.

4. Using suction cups, remove the back window.

b. 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.

c. Using a brush or sponge, apply Primer G to the edge of the back window and contact surface.

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 that which is specified,wipe off the primer with a clean shop rag before it dries.

d. Apply adhesive.
Adhesive: Part No. 08850-00801 or 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.

2. Load the sealer gun with the cartridge.

3. Apply adhesive to the back window, as shown in the illustration.

e. Install the windshield glass onto the vehicle body.
1. Using suction cups, position the back window 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 windshield glass have a small gap between them.

2. Lightly press the front surface of the windshield glass to ensure that the windshield glass is securely fitted to the vehicle body.

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

HINT: Apply adhesive onto the windshield glass rim.

f. Tighten the 2 nuts.

Torque: 7.8 N.m (80 kgf.cm, 69 in.lbf)

35. CHECK FOR LEAKAGE AND REPAIR
a. Conduct a leak test after the adhesive has completely hardened.
b. Seal any leakage with auto glass sealer.

36. INSTALL COAT HOOK
37. INSTALL QUARTER INSIDE TRIM BOARD LH
38. INSTALL QUARTER INSIDE TRIM BOARD RH

HINT: Follow the same procedures as for the quarter inside trim board LH.

39. INSTALL ROOF SIDE GARNISH INNER LH (ACCESS CAB)
40. INSTALL ROOF SIDE GARNISH INNER RH (ACCESS CAB)

HINT: Follow the same procedures as for the roof side garnish inner LH.

41. INSTALL QUARTER TRIM PANEL LOWER LH
42. INSTALL QUARTER TRIM PANEL LOWER RH

HINT: Follow the same procedures as for the quarter inside trim board LH.

43. INSTALL LUGGAGE COMPARTMENT SIDE TRAY (DOUBLE CAB)
44. INSTALL REAR SEAT BACK HINGE SUB-ASSEMBLY CENTER (DOUBLE CAB)
45. INSTALL LUGGAGE COMPARTMENT SIDE TRAY (DOUBLE CAB)
46. INSTALL BACK PANEL TRIM (ACCESS CAB, REGULAR CAB (SEPARATE SEAT TYPE))
47. INSTALL BACK PANEL TRIM COVER (REGULAR CAB (SEPARATE SEAT TYPE))
48. INSTALL JACK ASSEMBLY (REGULAR CAB (SEPARATE SEAT TYPE))
49. INSTALL BACK PANEL GARNISH UPPER (REGULAR CAB)
50. INSTALL BACK PANEL TRIM COVER (REGULAR CAB (BENCH SEAT TYPE))
51. INSTALL BACK PANEL TRIM COVER (EXCEPT DOUBLE CAB)
52. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH (DOUBLE CAB)
53. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP RH (DOUBLE CAB)

HINT: Follow the same procedures as for the rear door opening trim weatherstrip LH.

54. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP LH (EXCEPT DOUBLE CAB)
55. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP RH (EXCEPT DOUBLE CAB)

HINT: Follow the same procedures as for the front door opening trim weatherstrip LH.

56. INSTALL ROOF SIDE INNER GARNISH CAP LH (ACCESS CAB)
57. INSTALL ROOF SIDE INNER GARNISH CAP RH (ACCESS CAB)

HINT: Follow the same procedures as for the roof side inner garnish LH.

58. INSTALL REAR DOOR SCUFF PLATE LH (EXCEPT REGULAR CAB)

59. INSTALL REAR DOOR SCUFF PLATE RH (EXCEPT REGULAR CAB)

HINT: Follow the same procedures as for the rear door scuff plate LH.

60. INSTALL FRONT DOOR SCUFF PLATE LH (EXCEPT DOUBLE CAB)

61. INSTALL FRONT DOOR SCUFF PLATE RH (EXCEPT DOUBLE CAB)

HINT: Follow the same procedures as for the front door scuff plate LH.

62. INSTALL REAR SEAT BACK HINGE SUB-ASSEMBLY LH (DOUBLE CAB)
63. INSTALL REAR SEAT BACK HINGE SUB-ASSEMBLY RH (DOUBLE CAB)
64. INSTALL REAR SEAT BACK ASSEMBLY LH (DOUBLE CAB)
65. INSTALL REAR SEAT BACK ASSEMBLY RH (DOUBLE CAB)
66. INSTALL REAR SEAT BACK HINGE COVER (DOUBLE CAB)