Back Window Glass: Service and Repair

REMOVAL







1. Remove the Polyurethane (PU) adhesive cap and heat the PU adhesive for a minimum of 30 minutes.







2. Remove the parcel shelf.
1. Release the backrest latch trim panels.
2. Remove the left-hand safety belt trim panel.
3. Move the parcel shelf forwards.
3. Remove the C-pillar trim panel.







4. Detach the rear of the headliner from the roof panel.
^ Remove the retaining clips.







5. Place two 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 electrical connector and remove the high mounted stoplamp.







9. From inside the vehicle, using a suitable direct glazing cutter, cut the PU adhesive to the given maximum depths.
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.







10. With the aid of another technician, use glazing suction cups to remove the rear window glass.

INSTALLATION
1. Carefully remove the remaining part of the locating pegs from the rear window glass flange.







2. Carefully trim the remaining PU adhesive from the rear window glass flange to leave approximately 1 mm of trimmed PU adhesive adhered to the flange.

CAUTION: Do not touch the adhesive surfaces re-bonding will be impaired.

3. Check the rear window glass flange for damaged sheet metal, rust or foreign material which may have caused, or may cause, glass breakage.
4. Using a hot air gun, apply warm air (25°C) to the rear window glass 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 the bonding surfaces are free of moisture.

5. Prepare the glass, rear window glass flange and trimmed PU adhesive in accordance with the instructions supplied with the PU adhesive kit.







6. Apply the PU adhesive in a continuous bead of between 8 and 10 mm in height to the rear window glass 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 must be overlapped by 20 mm.

7. Install the rear window glass weatherstrip.







8. With the aid of another technician, use glazing suction cups to install the rear window glass.
^ Press firmly and evenly into position.
9. Using suitable tape, secure the rear window glass in the correct position until the PU adhesive has cured.

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.







10. If the ambient temperature falls below 10°C, use a hot air gun and apply warm air (25°C) continuously for 15 minutes (inside or outside the vehicle).







11. Connect the high mounted stoplamp electrical connector.







12. Install the high mounted stoplamp.







13. Install the headliner.
^ Remove the spacers.







14. Connect the heated rear window electrical connectors.
15. Install the C-pillar trim panel.







16. Install the rear parcel shelf.
1. Position the parcel shelf.
2. Install the left-hand safety belt trim panel.
3. Attach the backrest latch trim panels.