Toyota CH-R Service Manual: Installation

INSTALLATION

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 window glass.

(2) Clean the outer circumference of the back window glass with a non-residue solvent.

NOTICE:

  • Do not touch the back window glass surface after cleaning it.
  • Even if using a new back window glass, clean it with a nonresidue solvent.

2. INSTALL BACK DOOR GLASS SPACER (for Upper Side)

(a) Using a brush or sponge, coat the installation area of the new back door glass spacer with primer G.

NOTICE:

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

HINT:

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

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

*a

Back Side of Back Door Glass

*b

Ceramic Notch

3. INSTALL BACK DOOR GLASS SPACER (for Side)

(a) Using a brush or sponge, coat the installation area of the new back door glass spacer with primer G.

NOTICE:

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

HINT:

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

(b) Install the 4 new back door glass spacers to the back door glass as shown in the illustration.

*a

Back Side of Back Door Glass

*b

Ceramic Notch

4. INSTALL BACK WINDOW LOWER MOULDING

(a) Using a brush or sponge, coat the installation area of a new back window lower moulding with primer G.

NOTICE:

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

HINT:

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

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

Standard Dimension:

Area

Dimension

a

10.3 mm (0.406 in.)

b

18.5 mm (0.728 in.)

c

15.1 mm (0.594 in.)

*a

Back Side of Back Door Glass

5. INSTALL NO. 2 BACK WINDOW GLASS SPACER

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

NOTICE:

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

HINT:

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

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

*a

Back Side of Back Door Glass

*b

Ceramic Notch

6. INSTALL NO. 1 BACK WINDOW GLASS SPACER

HINT:

Use the same procedure as for the No. 2 back window glass spacer.

7. INSTALL BACK WINDOW OUTSIDE MOULDING LH

(a) Using a brush or sponge, coat the installation area of a new back window outside moulding LH with primer G.

NOTICE:

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

HINT:

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

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

Standard Dimension:

Area

Dimension

a

9.9 mm (0.390 in.)

*a

Back Side of Back Door Glass

8. INSTALL BACK WINDOW OUTSIDE MOULDING RH

HINT:

Use the same procedure as for the LH side.

9. INSTALL BACK DOOR GLASS

(a) Clean and shape the contact surface of the vehicle body.

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

NOTICE:

Leave as much adhesive on the vehicle body as possible.

(b) Back door glass preliminary installation procedures:

(1) Install the suction cups to the back door glass.

(2) Temporarily place the back door glass onto the vehicle body and set it so that the gap between the body and upper portion and sides of the back door glass is even.

(c) 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.

(3) Align the matchmarks on the back door glass and back door panel.

NOTICE:

Check that the No. 1 and No. 2 back window glass spacers are engaged to the back door panel correctly.

(4) Remove the back door glass.

*a

Matchmark

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

NOTICE:

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

HINT:

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

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

*a

Back Side of Back Door Glass

*b

Adhesive Positioning Center

*c

Ceramic Notch

-

-

Primer G

-

-

Standard Dimension:

Area

Dimension

a

7.0 mm (0.276 in.) or more

b

15.3 mm (0.602 in.)

c

7.0 mm (0.276 in.) or more

d

18.5 mm (0.728 in.)

e

7.0 mm (0.276 in.) or more

f

12.3 mm (0.484 in.)

NOTICE:

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

HINT:

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

(f) 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.

Standard Dimension:

Area

Dimension

a

12.0 to 15.0 mm (0.472 to 0.591 in.)

b

8.0 to 11.0 mm (0.315 to 0.433 in.)

*a

Nozzle

(2) Load the sealer gun with the cartridge.

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

*a

Back Side of Back Door Glass

*b

Adhesive Positioning Center

*c

Ceramic Notch

-

-

Adhesive

-

-

Standard Dimension:

Area

Dimension

a

15.3 mm (0.602 in.)

b

18.5 mm (0.728 in.)

c

12.3 mm (0.484 in.)

HINT:

Apply adhesive to the ceramic notches.

(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 No. 1 and No. 2 back window glass spacers 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 No. 1 back window glass spacer and No. 2 back window glass spacer.

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 vehicle.

(h) Connect each connector and engage each clamp.

10. CONNECT NO. 1 BACK DOOR WIRE

(a) Connect the 2 connectors to the back door glass.

11. INSTALL REAR LIGHT ASSEMBLY (for Bulb Type)

Click here

12. INSTALL REAR LIGHT ASSEMBLY (for LED Type)

Click here

13. INSTALL REAR WIPER MOTOR ASSEMBLY

Click here

14. 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.

15. INSTALL REAR SPOILER

Click here

    Removal
    REMOVAL PROCEDURE 1. REMOVE REAR SPOILER Click here 2. REMOVE REAR WIPER MOTOR ASSEMBLY Click here 3. REMOVE REAR LIGHT ASSEMBLY (for Bulb Type) Click here 4. REMOVE REAR LIGHT ASS ...

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