Toyota Prius: Back Door Glass

NOTICE:

• After cutting off the old adhesive remaining on the adhesion surface, apply new adhesive within 2 hours.
• If the cut surface of the old adhesive is left exposed for a long time, the adhesion strength will be reduced, so apply the new adhesive quickly.

NOTICE:

• After cutting off the old adhesive remaining on the adhesion surface, apply new adhesive within 2 hours.
• If the cut surface of the old adhesive is left exposed for a long time, the adhesion strength will be reduced, so apply the new adhesive quickly.

1. Apply soapy water to the area around the adhesive.
2. Insert a windshield knife into the adhesive between the back door glass and Toyota Prius vehicle body.
3. While keeping the windshield knife perpendicular to the outer surface of the back door glass, cut the adhesive by pulling the windshield knife around the back door glass.

   NOTICE:

   • Do not pry the back door glass with the windshield knife.
   • Do not use a windshield knife to cut the adhesive on the lower side of the back door glass.
   • When separating the back door glass, be careful not to damage the paint or interior and exterior ornaments.

   HINT:

   Insert the windshield knife in an area where the gap between back door glass and Toyota Prius vehicle body is large.

1. Pass a piano wire between the Toyota Prius vehicle body and glass from the interior, as shown in the illustration.
2. Tie both wire ends to wooden blocks or similar objects that can serve as handles.
3. Cut the adhesive by pulling the piano wire around the back door glass.

   NOTICE:

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

NOTICE:

• To prevent the back door glass from falling when performing this operation, be sure to hold the back door glass using suction cups.
• Be careful not to drop the back door glass.
• Leave as much adhesive on the back door panel as possible when removing the back door glass.

NOTICE:

• Be careful not to damage the back door glass.
• Be sure to replace the back door window moulding with a new one.

NOTICE:

• Be careful not to damage the back door glass.
• Be sure to replace the No. 1 back window glass spacer with a new one.

NOTICE:

• Be careful not to damage the back door glass.
• Be sure to replace each back door glass spacer with a new one.

NOTICE:

• Be careful not to damage the back door glass.
• Be sure to replace the back window glass adhesive dam with a new one.

NOTICE:

• Make sure to use Toyota Genuine Windshield Glass Adhesive (High Modulus Type) or an equivalent high modulus adhesive.
• After cutting off the old adhesive remaining on the adhesion surface, apply new adhesive within 2 hours.
• If the cut surface of the old adhesive is left exposed for a long time, the adhesion strength will be reduced, so apply the new adhesive quickly.

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.

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.

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.

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.

NOTICE:

• After cutting off the old adhesive remaining on the adhesion surface, apply new adhesive within 2 hours.
• If the cut surface of the old adhesive is left exposed for a long time, the adhesion strength will be reduced, so apply the new adhesive quickly.

1. Using 2 suction cups, place a back door glass in the correct position.
2. Check that the whole contact surface of the back door glass rim is perfectly even.
3. Align the matchmarks on the back door glass and back door panel.

   NOTICE:

   Check that the back window glass clips are engaged to the back door panel correctly.

4. Remove the back door glass.
5. Using a brush, coat the installation surfaces on the back door panel with body primer.

   NOTICE:

   • Do not coat the adhesive with 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.

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:

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

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

   Standard Dimension:

   Area	Dimension	Area	Dimension
   a	10.0 to 13.0 mm (0.394 to 0.512 in.)	b	6.0 to 9.0 mm (0.197 to 0.236 in.)

2. Load the sealer gun with cartridge.

1. Using 2 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 No. 1 back window glass spacer and No. 2 back window glass spacer are engaged to the back door panel correctly.
   • Check the clearance between the back door panel and back door glass.
2. Lightly press the front surface of the back door glass to ensure a close fit.

   HINT:

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

3. Using a scraper, remove any excess or protruding adhesive.
4. 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 Toyota Prius vehicle.