Toyota Highlander Service Manual: Back door glass

COMPONENTS

REPLACEMENT

HINT:

• The installation procedures are the removal procedures in reverse order. However, only installation procedures requiring additional information are included.
• A bolt without a torque specification is shown in the standard bolt chart (see page 03-2 ).

1. REMOVE ASSIST STRAP HOLE COVER (See page 75-20 )

2. REMOVE ASSIST STRAP ASSY RH (See page 75-20 )

3. REMOVE BACK DOOR TRIM PANEL ASSY (See page 75-20 )

4. REMOVE BACK WINDOW PANEL TRIM UPPER (See page 75-20 )

5. REMOVE BACK DOOR TRIM COVER RH (See page 75-20 )

6. REMOVE BACK DOOR TRIM COVER LH (See page 75-20 )

7. REMOVE REAR WIPER ARM ASSY (See page 66-12 )

8. REMOVE REAR SPOILER (W/ REAR SPOILER) (See page 76-8 )

9. REMOVE BACK DOOR GLASS

(a) Disconnect the connector.

(b) From the interior, insert piano wires between the vehicle body and glass, as shown in the illustration.

(c) Tie objects that can serve as handles (for example, wooden blocks) to all wire ends.

HINT: Apply protective tape to the outer surface of the vehicle body to prevent its surface from being scratched.

NOTICE:

• When separating the glass from the vehicle, be careful not to damage the vehicle's paint or interior/exterior ornaments.
• To prevent the safety pad from being scratched when removing the glass, place a plastic sheet between the piano wire and safety pad.

(d) Cut through the adhesive by pulling the piano wire around the glass.

(e) Using a suction cup, remove the glass.

NOTICE: Leave as much adhesive on the vehicle body as possible when removing the glass.

10. CLEAN BACK DOOR GLASS

(a) Using a scraper, remove the damaged spacers, moulding and adhesive sticking to the glass.

(b) Clean the outer circumference of the glass with white gasoline.

NOTICE:

• Do not touch the glass surface after cleaning it.
• Even if using new glass, clean the glass with white gasoline.

11. INSTALL BACK DOOR GLASS SPACER NO.1

(a) Coat the installation part of the spacers with Primer G.

NOTICE:

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

(b) Install 2 new spacers onto the glass, as shown in the illustration.

12. INSTALL BACK WINDOW GLASS SPACER NO.2

13. INSTALL BACK WINDOW MOULDING OUTSIDE

(a) Coat the installation part of the back window moulding outside with Primer G.

NOTICE:

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

(b) Install a new back window moulding outside, as shown in the illustration.

Specification:

14. INSTALL BACK DOOR GLASS

(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.

NOTICE: Be careful not to damage the vehicle body.

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

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

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

(b) Using a brush, coat the exposed part of the vehicle body with Primer M.

NOTICE:

• Allow the primer coating to dry for 3 minutes or more.
• Do not coat the adhesive with Primer M.
• Throw away any leftover Primer M.
• Do not apply too much Primer M.

(c) Using a brush or sponge, coat the edge of the glass and the contact surface with Primer G.

HINT: If the area other than that specified is coated by accident, wipe off the primer with a clean shop rag before it dries

NOTICE:

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

(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 described in the table below.

Usage timeframe:

2. Load the sealer gun with the cartridge.
3.  Coat the glass with adhesive, as shown in the illustration.

Specification:

(e) Install the back window glass to the vehicle body.

1.  Hold the back window glass in place securely with protective tape or equivalent until the adhesive hardens.

NOTICE:

• Allow the primer coating to dry for 3 minutes or more.
• Check that the spacers are attached to the vehicle body correctly.
• Check that the vehicle body and glass have a small gap between them.

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

NOTICE: Do not drive the vehicle for the amount of time described in the table below.

Minimum time:

3. Hold the glass in place securely with a protective tape or equivalent until the adhesive hardens.

15. CHECK FOR LEAKS AND REPAIR

(a) Conduct a leak test after the adhesive has completely hardened.

(b) Seal any leaks with auto glass sealer.

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