Liftgate Window Glass: Service and Repair

Glass - Tailgate Upper

Service Repair No - 76.31.22

The following equipment is required:
^ Cutting wire and handles
^ Glazing knife
^ Glass replacement kit
^ Sealant applicator gun
^ Suction cups
^ A felt covered table or stand to support glass

Remove

1. Remove rear wiper arm.
2. Remove tailgate trim casing.
3. Remove tailgate inner side finishers.
4. Remove tailgate glass outer finisher.







5. Disconnect 3 multiplugs from tailgate glass.
6. Protect exterior body work adjacent to rear screen.







7. From inside vehicle, carefully cut through sealant securing lower edge of windscreen with a glazing knife. It is not practical to use a Kent knife as the windscreen is very close to body.
8. If necessary, use cutting wire to cut through any remaining sealant securing top and sides of windscreen.
9. Attach suction cups and with assistance, remove windscreen and place on stand.

CAUTION: Lay glass on felt covered supports and be careful not to damage the obscuration band. Do not stand on edge as this can cause chips which subsequently develop into cracks.







10. Remove 2 windscreen support blocks from body.

Refit

1. Carefully remove sealant from body to leave a smooth surface.
2. Original screen: Carefully cut back sealant to obtain a smooth surface without damage to obscuration band.
3. Fit finisher to screen.
4. Fit support blocks to body.
5. Fit screen to body and centralise in aperture.







6. Use masking tape to establish reference marks as an alignment aid.
7. Remove windscreen and place on stand.
8. Clean sealant face on body and windscreen with solvent.
9. Apply etch primer to any bare metal on body.
10. Apply primer over etch primer.
11. Apply screen primer to sealant face on windscreen and allow to cure.
12. Apply activator over old sealant on body and allow to cure.
13. Fit pre-cut nozzle to sealer cartridge, remove lid, shake out crystals and fit cartridge to applicator gun. If necessary modify the nozzle to achieve required bead section.







14. Apply a continuous bead of sealant to windscreen as shown,
^ 'A' = 8 mm (0.31 in)
^ 'B' = 11 mm (0.43 in).

15. With assistance, fit and align windscreen. Lightly press windscreen to seat sealer.
16. Remove protective covers and tape.
17. Connect multiplugs to tailgate glass.
18. Test sealer for leaks, apply additional sealer if necessary. If water is used, allow sealer to dry before testing. Spray water around glass and check for leaks. Mark any area that leaks. Dry glass and sealer then apply additional sealer.
19. Fit tailgate inner side finishers.
20. Fit tailgate trim casing.
21. Fit rear wiper arm.