Toyota Yaris: Back Door Glass / Installation

Toyota Yaris XP210 (2020-2022) Reapir and Service Manual / Vehicle Exterior / Window / Glass / Back Door Glass / Installation

INSTALLATION

CAUTION / NOTICE / HINT

NOTICE:

Make sure to use Toyota Genuine Windshield Glass Adhesive (High Modulus Type) or equivalent.

PROCEDURE

1. CLEAN BACK DOOR GLASS

(a) When reusing the back door glass:

(1) Using a scraper, remove any remaining adhesive residue from the back window 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 window glass surface after cleaning it.
  • Even if using a new back door glass, clean it with a non-residue solvent.

2. INSTALL BACK DOOR GLASS SPACER

(a) Using a brush or sponge, coat the installation area of the 2 back door glass spacers with the glass primer.

NOTICE:

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

HINT:

If an area other than specified is coated by accident, wipe off the glass primer with a clean piece of cloth before it dries.

(b) Install 2 new back door glass spacers to the back door glass as shown in the illustration.

*a

Back Side of Back Door Glass

*b

Ag Print Mark

3. INSTALL BACK WINDOW GLASS CLIP LH

(a) Using a brush or sponge, coat the installation area of the back window glass clip LH with the glass primer.

NOTICE:

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

HINT:

If an area other than specified is coated by accident, wipe off the glass primer with a clean piece of cloth before it dries.

(b) Install a new back window glass clip LH to the back door glass as shown in the illustration.

*a

Back Side of Back Door Glass

*b

Ag Print Mark

4. INSTALL BACK WINDOW GLASS CLIP RH

HINT:

Use the same procedure as for the LH side.

5. INSTALL NO. 1 BACK WINDOW OUTSIDE MOULDING LH

(a) Using a brush or sponge, coat the installation area of the No. 1 back window outside moulding LH with the glass primer.

NOTICE:

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

HINT:

If an area other than specified is coated by accident, wipe off the glass primer with a clean piece of cloth before it dries.

(b) Install a new back window outside moulding LH to the back door glass as shown in the illustration.

*a

Back Side of Back Door Glass

*b

Ag Print Mark

Standard Dimension:

Area

Dimension

Area

Dimension

a

0 to 1.0 mm (0 to 0.0394 in.)

b

0 to 2.0 mm (0 to 0.0787 in.)

c

0 to 3.0 mm (0 to 0.118 in.)

-

-

6. INSTALL NO. 1 BACK WINDOW OUTSIDE MOULDING RH

HINT:

Use the same procedure as for the LH side.

7. INSTALL NO. 2 BACK WINDOW GLASS ADHESIVE DAM

(a) Using a brush or sponge, coat the installation area of the No. 2 back window glass adhesive dam with the glass primer.

NOTICE:

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

HINT:

If an area other than specified is coated by accident, wipe off the glass primer with a clean piece of cloth before it dries.

(b) Install a new No. 2 back window glass adhesive dam to the back door glass as shown in the illustration.

*a

Back Side of Back Door Glass

*b

Ag Print Mark

8. INSTALL BACK WINDOW GLASS ADHESIVE DAM

(a) Using a brush or sponge, coat the installation area of the back window glass adhesive dam with the glass primer.

NOTICE:

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

HINT:

If an area other than specified is coated by accident, wipe off the glass primer with a clean piece of cloth before it dries.

(b) Install a new back window glass adhesive dam to the back door glass as shown in the illustration.

*a

Back Side of Back Door Glass

*b

Ag Print Mark

9. INSTALL BACK DOOR GLASS

(a) Clean and shape the contact surface of the back door panel.

(1) Using a knife, cut away excess adhesive on the contact surface of the back door panel as shown in the illustration.

Adhesive

NOTICE:

Leave as much adhesive on the back door panel as possible.

(b) 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.

NOTICE:

Check that the back window glass clip LH and back window glass clip RH are engaged to the back door panel correctly.

(3) When using a new back door glass:

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

    *a

    Matchmark

(4) Remove the back door glass.

(c) Using a brush, coat the installation surfaces on the back door panel with the body primer.

NOTICE:

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

HINT:

If an area other than specified is coated by accident, wipe off the body primer with a clean piece of cloth before it dries.

(d) Using a brush or sponge, coat the adhesive application area with the glass primer.

*1

Back Window Glass Adhesive Dam

*2

No. 2 Back Window Glass Adhesive Dam

*a

Back Side of Back Door Glass

-

-

Glass Primer

-

-

Standard Dimension:

Area

Dimension

Area

Dimension

a

11 mm (0.433 in.) or more

b

11 mm (0.433 in.) or more

c

22.5 mm (0.886 in.) or more

d

48.1 mm (1.894 in.)

NOTICE:

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

HINT:

If an area other than specified is coated by accident, wipe off the glass primer with a clean piece of cloth before it dries.

(e) Prepare to apply adhesive to the back door glass.

Adhesive:

Toyota Genuine Windshield Glass Adhesive (High modulus type) or equivalent

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

*a

Nozzle

Adhesive

Standard Dimension:

Area

Dimension

a

12 to 15 mm (0.472 to 0.591 in.)

b

8.0 to 11 mm (0.315 to 0.433 in.)

(2) Load the sealer gun with the cartridge.

(f) Apply adhesive to the back door glass as shown in the illustration.

*1

Back Window Glass Adhesive Dam

*2

No. 2 Back Window Glass Adhesive Dam

*a

Back Side of Back Door Glass

-

-

Adhesive

-

-

Standard Dimension:

Area

Dimension

Area

Dimension

a

19.6 mm (0.772 in.)

b

29.1 mm (1.15 in.)

c

55.1 mm (2.17 in.)

-

-

(g) Install the back door glass.

(1) Using suction cups, position the back door glass so that the matchmarks are aligned, and press it in gently along the rim.

NOTICE:

  • Check that the back window glass clip LH and back window glass clip RH are engaged to the back door panel correctly.
  • Check the clearance between the back door panel and back door glass.

*a

Matchmark

(2) Lightly press the outer surface of the back door glass to ensure a close fit and engage the back window glass clip LH and back window glass clip RH.

HINT:

Press the glass with force of 98 N (10 kgf, 22.0 lbf) or more.

(h) Using a scraper, remove any excess or protruding adhesive.

(i) Hold the back door glass using protective tape until the applied adhesive becomes hard.

HINT:

Follow the instructions supplied by the adhesive manufacturer or in the corresponding instruction manual for the minimum amount of time necessary to wait before driving the vehicle.

(j) Connect each connector and engage each clamp.

10. INSTALL REAR SPOILER ASSEMBLY

Click here

11. INSTALL BACK DOOR OUTSIDE GARNISH SUB-ASSEMBLY

Click here

12. INSPECT FOR LEAK

(a) After the adhesive has hardened, apply water from the outside of the vehicle. Check that no water leaks into the cabin.

(b) If water leaks into the cabin, allow the water to dry and add adhesive.

(c) Remove the protective tape and matchmark.

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