Removal and Replacement
WINDOW GLASS - REARSpecial Tool(s)
Special Tool(s):
Material
Material:
Removal
1. Remove the parcel shelf.
2. Remove the 2 garment hangers and 2 pin-type retainers and release the rear of the headliner from the roof panel.
3. Place 2 blocks of suitable material between the headliner and the roof panel to act as spacers.
4. Disconnect the 2 heated rear window glass electrical connectors.
5. Before cutting the urethane adhesive, remove dirt and other foreign material from the pinch weld area.
- Use a clean shop towel or oil-free compressed air.
6. NOTE: Refer to manufacturer's instructions before using the tool.
Lubricate the urethane adhesive with water to aid the Interior Auto Glass Cut-Out Knife Kit when cutting the urethane adhesive.
7. WARNING:
- Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury.
- Wear protective gloves when handling components or parts that have pointed or sharp edges. Failure to follow this instruction may result in serious personal injury.
CAUTION:
- To avoid rust formation, use extreme care not to scratch the paint or primer, or otherwise damage the pinch weld during glass removal.
- Make sure the cutting blades are changed where the cutting depth changes to avoid damage to the body and trim panels.
NOTE:
- Insert the blade into the special tool so that the flat side is against the glass. This will leave the entire urethane adhesive bead on the pinch weld and allow a dry fit of the replacement rear window glass.
- Some resistance may be encountered when cutting through the glass locating pegs in the upper corners of the glass.
Insert the special tool at the upper center of the rear window glass and work toward the bottom corners.
8. Using the special tool, distance the rear window glass from the body.
9. Using the special tool, cut the remaining urethane adhesive and remove the rear window glass and place on a stable work surface.
Installation
CAUTION: When installing urethane-installed glass parts, the vehicle must not be driven until the urethane has cured. Adequate cure time is specified on the drive away chart for each urethane product as the temperatures and humidity vary. Inadequate or incorrect curing can adversely affect the retention of the rear window glass.
NOTE: For additional material guidelines, refer to the manufacturer's installation information.
1. Dry fit the rear window glass to the existing urethane adhesive on the body pinch weld.
- Make alignment marks with tape or non-staining grease pencil on the rear window glass and the body to aid in the installation alignment of the rear window glass.
2. Remove the rear window glass and place on a stable work surface with the interior side of the glass facing up.
3. WARNING: Repair any corrosion found on the pinch weld. The pinch weld is a structural component of the vehicle. Corrosion left unrepaired may reduce the structural integrity of the vehicle. Failure to follow this instruction may result in serious injury to vehicle occupant(s).
NOTE: Avoid scratching the pinch weld. Repair all minor scratches or exposed metal on the pinch weld following glass primer manufacturer's recommendations before installation of the glass. Be sure to use the same brand and cure-rate products for the adhesive and primer.
Using an appropriate tool, trim the urethane adhesive leaving a 1-2 mm (0.04-0.08 in) base of original equipment urethane on the pinch weld.
4. Using a clean shop towel, brush or oil-free compressed air, clean the pinch weld area around the existing urethane. Remove any foreign material or water that may have entered during glass removal.
5. If installing the original rear window glass, remove the excess urethane adhesive.
6. Clean the inside of the rear window glass with glass cleaner.
7. NOTE:
- Be sure to use the same brand and cure-rate products for the adhesive and primer. Do not mix different brands of urethane and primer. Refer to the Material Chart.
- Sika uses the same black primer for the glass and pinch weld area.
If installing a new rear window glass, apply urethane glass primer according to the manufacturer's instructions. Allow at least 6 minutes to dry.
8. Cut the urethane adhesive applicator tip to the specification.
9. NOTE:
- The rear window glass must be positioned within 10 minutes of applying the urethane adhesive.
- Use either a high-ratio, electric or battery-operated caulk gun that will apply the urethane with less effort and a continuous bead.
Apply a bead of urethane adhesive on top of the existing trimmed urethane adhesive bead on the pinch weld. Make sure that all gaps in the urethane adhesive are smoothed into one continuous bead starting and ending at the bottom of the rear window near the center.
10. WARNING: Do not drive vehicle until the urethane seal has cured. Follow urethane manufacturer's curing directions. Inadequate or incorrect curing of the urethane seal will adversely affect glass retention. Failure to follow these instructions may result in serious injury to vehicle occupant(s).
CAUTION: Before positioning the rear window glass, open vehicle windows to prevent the air pressure of closing doors from affecting the adhesive bond. Using the alignment marks made previously, position the rear window glass on the pinch weld.
Using the alignment marks made previously, position the rear window glass on the pinch weld.
11. NOTE: The urethane adhesive must cure for a minimum of one hour before testing for air or water leaks.
After the urethane has cured, check the rear window glass seal for air or water leaks through the urethane adhesive bead and add urethane adhesive as necessary.
12. Position the headliner, install the pin-type retainers and garment hangers.
13. Connect the 2 heated rear window glass electrical connectors.
14. Install the parcel shelf.