Lexus ES: Installation

INSTALLATION

PROCEDURE

1. INSTALL NO. 1 BACK WINDOW GLASS STOPPER (for 2-piece Type)

(a) Install 2 new No. 1 back window glass stoppers to the vehicle body as shown in the illustration. HINT: Only 2-piece type back window glass stoppers are provided as supply parts. Use 2-piece type stoppers as replacements even if 1-piece type stoppers were originally installed.

2. INSTALL NO. 2 BACK WINDOW GLASS STOPPER (for 2-piece Type)

(a) Using a brush or sponge, coat the installation area of 2 new No. 2 back window glass stoppers with 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 No. 2 back window glass stoppers to the back window glass as shown in the illustration. Standard Dimension: Area Dimension a 14.2 to 15.2 mm (0.559 to 0.598 in.) HINT: Only 2-piece type back window glass stoppers are provided as supply parts. Use 2-piece type stoppers as replacements even if 1-piece type stoppers were originally installed.

*A Back Side *a Ceramic Notch *b Back Window Glass Edge Side

3. INSTALL BACK WINDOW OUTSIDE MOULDING

(a) Using a brush or sponge, coat the installation area of a new back window outside moulding with 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 the new back window outside moulding to the back wind glass as shown in the illustration. Standard Dimension: Area Dimension a 6.65 mm (0.262 in.)

*A Back Side *a Edge Of Curved Surface *b Same Length

4. INSTALL BACK WINDOW GLASS ADHESIVE DAM

(a) Using a brush or sponge, coat the installation area of a new back window glass adhesive dam with 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 window glass as shown in the illustration.

5. INSTALL BACK WINDOW GLASS SUB-ASSEMBLY

(a) Position the back window glass sub-assembly. (1) Using suction cups, place the back window glass sub-assembly in the correct position. (2) Check that the whole contact surface of the back window glass sub-assembly rim is perfectly even. (3) Align the matchmarks on the back window glass sub-assembly and vehicle body. NOTICE: Check that the back window glass stoppers are engaged to the vehicle body correctly. (4) Remove the back window glass sub-assembly.

*a Matchmark

(b) Using a brush, coat the installation surface on the vehicle body with 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.

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

*A	Back Side	-	-
*a	Adhesive Application Area	*b	Ceramic Notch
	Glass Primer	-	-

Standard Dimension:

(d) Apply adhesive to the back window glass sub-assembly.

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 window glass sub-assembly as shown in the illustration.

*A	Back Side	-	-
*a	Adhesive Positioning Center	*b	Ceramic Notch
	Adhesive	-	-

Standard Dimension:

HINT:

Apply adhesive to the ceramic notches.

(e) Install the back window glass sub-assembly.

(1) Using suction cups, position the back window glass sub-assembly so that the matchmarks are aligned, and press it in gently along the rim. NOTICE: Check that the back window glass stoppers are engaged to the vehicle body correctly. Check the clearance between the vehicle body and back window glass sub-assembly.

*a Matchmark

(2) Lightly press the outer surface of the back window glass sub-assembly to ensure that the back window glass is securely fit to the vehicle body.

HINT:

Press the glass with a 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 window glass sub-assembly 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.

(f) Connect each connector.

6. 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.

7. INSTALL PACKAGE TRAY TRIM PANEL ASSEMBLY (w/o Rear Sunshade)

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8. INSTALL NO. 2 PACKAGE TRAY TRIM PANEL ASSEMBLY (w/ Rear Sunshade)

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9. INSTALL PACKAGE TRAY TRIM PANEL ASSEMBLY (w/ Rear Sunshade)

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10. INSTALL REAR SEAT SHOULDER BELT COVER

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11. INSTALL CENTER STOP LIGHT SET

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12. CONNECT REAR SEAT OUTER BELT ASSEMBLY LH

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13. CONNECT REAR SEAT OUTER BELT ASSEMBLY RH

HINT:

Use the same procedure as for the LH side.

14. INSTALL ROOF HEADLINING ASSEMBLY

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