Back Window Glass: Service and Repair
REMOVAL
1. Heat the Polyurethane (PU) adhesive if necessary.
NOTE: Should the ambient temperature fall below 10°C, heat the cartridges for approximately 15 minutes by placing them on a warm radiator, or using a hot air gun set at approximately 25°C.
2. Remove the rear parcel shelf.
1 Remove the backrest latch covers.
^ Release the two retaining tangs.
2. Remove the left-hand safety belt cover.
3. Pull the parcel shelf forward.
3. Remove the C-pillar trim panel.
4. Detach the rear of the headliner.
^ Remove the headliner retaining clips.
5. Lower the headliner.
^ Place blocks of suitable material between the headliner and the roof panel to act as spacers.
6. Disconnect the heated rear window electrical connectors.
7. Detach the high mounted stoplamp.
8. Disconnect the high mounted stoplamp electrical connector.
9. From inside the vehicle cut the PU adhesive at the given maximum depths. Use the recommended blades, following the proprietary tool manufacturers instructions.
1. 30 mm.
2. 25 mm.
WARNING: WEAR GLOVES AND EYE PROTECTION WHEN WORKING WITH THE GLASS CUTTING TOOL AS THE CUTTING OPERATION MAY PRODUCE SPLINTERS. WHEN USING THE CUTTER WEAR EAR PROTECTORS. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
CAUTION: Make sure the cutting blades are changed where the cutting depth changes to avoid damage to the body and trim panels.
NOTE:
^ Some resistance may be encountered when cutting through the glass locating pegs in the bottom corners of the glass.
^ Carefully remove the remaining part of the locating pegs from the window opening flange.
10. With the aid of another technician, use suction cups to remove the rear window glass.
INSTALLATION
1. Remove the excess PU adhesive from the opening flange.
^ Carefully trim the remaining PU adhesive from the rear window opening to leave approximately 1 mm of trimmed PU adhesive adhered to the opening flange.
CAUTION:
^ During the curing period of the PU adhesive, the door windows must be left open to avoid a build up of pressure when the doors are opened and closed.
^ Avoid touching the trimmed surface as this will inhibit the bonding of the new adhesive.
2. Check the pinch weld sealing area for damaged sheet metal, rust or foreign material which may have caused, or may cause glass breakage.
3. Using a hot air gun, apply warm air (25°C) to the rear window opening flange and glass bond line to remove all traces of moisture.
CAUTION: To make sure that the PU adhesive cures, it is essential that all bonding surfaces are free of moisture.
4. Prepare the glass, rear window opening flange and trimmed PU adhesive in accordance with the instructions supplied with the adhesive kit.
5. Apply a thin continuous bead of PU adhesive to the edge of the rear window glass.
NOTE:
^ Discard the first 100 mm of PU adhesive as this may have a reduced working time.
^ To avoid water leaks, any breakage in the continuous bead should be overlapped by 20 mm.
6. Install the rear window glass weatherstrip.
7. Apply the PU adhesive in a continuous bead of between 11 and 15 mm height to the rear window flange along the bond line.
NOTE:
^ Discard the first 100 mm of PU adhesive as this may have a reduced working time.
^ To avoid water leaks, any breakage in the continuous bead should be overlapped by 20 mm.
8. With the aid of another technician, use suction cups to install the rear window glass.
NOTE: Firmly and evenly press in position; tape the glass in the correct position until the PU adhesive has cured.
9. Should the ambient temperature fall below 10°C, use a hot air gun at a distance of approximately 50 mm from the surface and apply warm air (25°C) continuously for 15 minutes (inside or outside the vehicle).
10. Connect the high mounted stoplamp electrical connector.
11. Install the high mounted stoplamp.
12. Install the headliner.
^ Remove the spacers.
13. Connect the heated rear window electrical connectors.
14. Install the C-pillar trim panel.
15. Install the rear parcel shelf.
1. Position the parcel shelf.
2. Install the left-hand safety belt cover.
3. Install the backrest latch covers.