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Home >> Volvo >> 2000 >> S40 L4-1.9L Turbo VIN 25 B4204T2 >> Repair and Diagnosis >> Windows and Glass >> Windows >> Window Glass >> Back Window Glass >> Service and Repair >> Removal and Replacement >> Replacing Rear Windshield

Replacing Rear Windshield






Replacing the rear windshield

Removing the rear windshield

Remove:
- the high-level stop lamp. See Tailgate components, changing Tailgate Components
- the rubber strip on the inside
- the wiper arm mechanism. See Tailgate wiper mechanism and motor Tailgate Wiper Mechanism And Motor
- the electrical terminals for the heated rear windshield
- the rear panel
- the tail lamp unit. See Replacing tail lamps (5 doors) Replacing Tail Lamps (5 Doors).
Push the wire through the PUR adhesive bead. Cut out the rear windshield in the same way as for the front windshield.

Note! Apply masking tape to the painted bodywork.

Install the window:
Check the PUR-bead on the tailgate. Even out using a chisel if necessary. A layer of approximately 1 mm can be left. Clean using Cleaner-H.
Check and replace (if necessary) the four spacers on the frame.
Cut away the PUR bead using a chisel if the window is to be reused.
Use glass activator to clean the area on which the PUR adhesive is to be applied. A layer of approximately 1 mm can be left.
Apply glass primer to the surface. Apply liberally without allowing to run. Let the primer dry until the surface is matte.
Remove the masking tape.

Note! Install a new inner rubber. Check that the rubber is not in contact with the windshield at any point. Adjust the flange if the rubber is against the windshield.




Install the trim strips. Bond the new trim strip approximately 5 mm from the outer edge and approximately 1 mm from the upper and the lower edges respectively. Install the trim strip. Start at the marker in position (A) on the left and right on the upper side of the rear windshield flange.
Install the weatherstrip.
Start at the marking (A) on the left and right-hand sides on the top of the rear windshield flange.
Apply PUR adhesive to the glass.
Install the windshield. Secure the windshield to the roof using a couple of pieces of tape.
Shut the tailgate completely before installing the windshield.

Install:
- the tailgate wiper motor. See Tailgate wiper mechanism and motor Tailgate Wiper Mechanism And Motor
- the wiper arm and the wiper blade. See Tailgate wiper mechanism and motor Tailgate Wiper Mechanism And Motor
- the electrical terminals for the heated rear windshield
- the high-level stop lamp. See Tailgate components, changing Tailgate Components
- the tail lamp unit and the rear windshield panel. See Replacing tail lamps (5 doors) Replacing Tail Lamps (5 Doors).

Removing the fixed side window

Preparations
- Prepare the rear seat.

Removing the C-post inner panel
- Remove the inner panel from the C-post.

Removing the D-post inner panel
- Remove the inner panel from the D-post.

Removing the seat belt (inertia) reel

Remove:
- The seat belt (inertia) reel. See Seat belts Service and Repair.

Disconnecting the radio antenna (if applicable)





Remove:
- The radio antenna connector (1). Use a weatherstrip tool.

Note! If the window is to be reused, ensure that the wiring for the antenna is not damaged.

Cutting the PUR bead. Step 1




- Cut along the marked edge and the PUR bead (2). Use the tool (3), P/N 9512786
- Use a short knife blade, P/N 9512787. Do not damage the paint!

Note! Use a soap solution. This will make cutting easier. Ensure that the headlining remains clean and is not damaged.

Cutting the PUR bead. Step 2




- Cut along the marked edge and the PUR bead (2). Use the tool (3), P/N 9512786. Do NOT cut off the guide pins (4)
- Use a long knife blade, P/N 9512788. Do not damage the paint!
- Hold the rear edge of the window a small distance from the bodywork so that the remaining section of the marked PUR bead (2) can be reached with a thin bladed knife.

Note! Use a soap solution. This will make cutting easier.

Installing fixed side windows

Installing rear side windows




- Install the side window. See Installation of rear side window Installation Of Rear Side Window
- When working with PUR on the body flange, see PUR on body flange Procedures
- Clean the area on the window where the PUR adhesive will be applied. Use cleaner H (black cap)
- Apply glass activator (yellow cap) to the area on the window where the PUR adhesive will be applied
- Apply glass primer (green cap) to the area on the window where the PUR adhesive will be applied
- Apply liberally without allowing to run
- Let the primer dry until the surface is matte
- Apply the PUR / RIM activator (blue cap) on the remaining PUR bead (5) on the body flange
- Load both the cartridges into the adhesive gun. Install the mixer pipes
- Apply adhesive to the window or to the body flange
- Press the window into the correct position by hand
- Secure with tape.

Installing the radio antenna (if applicable)





Install:
- The radio antenna connector (1).

Note! Do not damage the wiring for the antenna.

Installing the seat belt (inertia) reel

Install:
- The seat belt (inertia) reel. See Seat belts Service and Repair.

Installing the D-post inner panel
- Install the inner panel on the D-post.

Installing the C-post inner panel
- Install the inner panel on the C-post.

Finishing work
- Reposition the rear seat.

Repairing heating elements in the rear windshield Service and Repair.

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