Back Window Glass: Service and Repair

Rear Window Glass

Special Service Tools















Removal
1. Remove the parcel shelf.
2. Remove high mounted stoplamp.

3. NOTE: Right-hand shown, left-hand similar.

Disconnect the electrical connectors.







4. NOTE: Right-hand shown, left-hand similar.

Disconnect the electrical connector.







5. CAUTION: Make sure the rear window finisher insert is not bent on removal. Failure to follow this instruction may result in damage to the component.

Remove the rear window finisher







6. Apply protective tape around the rear rear window glass aperture.







7. Apply suitable protective tape to rear edge of the headliner.







8. Using a suitable long bladed tool, penetrate the windshield glass adhesive.







9. Dispense 20 ml of WK9L lubricant into the WK9 spray bottle, fill the spray bottle with water and mix.
10. Apply cutting lubricant to the windshield glass adhesive.
11. Prepare the cheese wire and cutting handle.
- Cut a suitable length of cheese wire.
- Install one of the cutting handles to the cheese wire.

12. Pass the free end of the cheese wire through the penetration and install the second cutting handle.







13. WARNING: When removing the rear window glass, personal protection must be worn. Failure to follow this instruction may result in personal injury.

CAUTION: Make sure the cheese wire cannot contacted the paintwork while the the rear window glass adhesive is being cut. Failure to follow this instruction may result in damage to the vehicle.

NOTE: Apply cutting lubricant to the cheese wire frequently through out the cutting process.

With assistance and exercising care to avoid damaging the paintwork, cut around the rear window glass commencing upwards and along the top.







14. Install the lifting handles to the window glass, with assistance carefully remove the rear window glass from the vehicle.







15. Remove the lifting handles from the rear windshield glass.

Installation

1. WARNING:
- If the rear window glass is being installed at a temperature of 23 degrees C (73 degrees F) or above make sure the vehicle is not driven for at least 1 hour after installation. Failure to follow this instruction may result in personal injury.
- If the rear window glass is being installed at a temperature of 11 degrees C (52 degrees F) to 23 degrees C (73 degrees F), make sure the vehicle is not driven for at least 1.5 hours after installation. Failure to follow this instruction may result in personal injury.
- If the rear window glass is being installed at a temperature of 5 degrees C (41 degrees F) to 11 degrees C (52 degrees F), make sure the vehicle is not driven for at least 2 hours after installation. Failure to follow this instruction may result in personal injury.
- If the rear window glass is being installed at a temperature below 5 degrees C (41 degrees F), use heat and make sure the windshield glass adhesive has set before the vehicle is driven. Failure to follow this instruction may result in personal injury.

CAUTION: When installing the rear window glass, do not strike it in any way as this will crack the glass. Failure to follow this instruction may result in damage to the vehicle.

NOTE:
- Make sure the rear window glass does not move out of position in the windshield glass aperture.
- If the original rear window glass is to be installed remove the residual adhesive from windshield glass mating surface.

Using the special tool, remove any residual adhesive from the body.







2. Make sure the new rear window glass surface is clean using Betawipe spirit.







3. Apply glass primer to the mating surface of the rear window glass.







4. Install the rear window finisher to the rear window glass.
- Install new rear window finisher retaining clips.







5. Apply glass primer to the mating face of the body flange.







6. Cut adhesive nozzle to achieve a triangular section bead 7 mm (0.28 in) wide by 10 mm (0.39 in) high.







7. Using a suitable pneumatic application gun, apply a uniform bead of adhesive to the windshield glass edge commencing at the bottom center and overlapping the ends approximately 20 mm (0.79 in).







8. CAUTION: When installing the rear window glass, do not strike it in any way as this will crack the rear window glass. Failure to follow this instruction may result in damage to the component.

With assistance carefully install the rear window glass into the aperture and press firmly into place.







9. Remove the lifting handles.

10. NOTE: Make sure the windshield glass does not move out of position in the windshield glass aperture.

Apply suitable adhesive tape to the top of the rear window glass.







11. Remove the protective tape around the rear rear window glass aperture.







12. Remove protective tape from rear edge of headliner.







13. CAUTION: Do not connect the electrical connectors for at least 1 hour after installation of the windshield glass. Failure to follow these instructions may result in damage to the rear window glass adhesive.

NOTE: Right-hand shown, left-hand similar.

Connect the electrical connector.







14. CAUTION: Do not connect the electrical connectors for at least 1 hour after installation of the windshield glass. Failure to follow these instructions may result in damage to the rear window glass adhesive.

NOTE: Right-hand shown, left-hand similar.

Connect the electrical connectors.







15. Install the high mounted stoplamp.
16. Install the parcel shelf.