Quarter Glass

NOTE:
- Put on gloves to protect your hands.
- Wear eye protection when removing the glass with piano wire.
- Use seat covers to avoid damaging any surfaces.

1. Remove these items:
- D-pillar trim
- Separation net cap
- Coat hanger

2. Pull the upper portion of the rear side trim panel back, then remove the C-pillar trim.
3. Pull down the rear side portion of the headliner as necessary.
4. Apply protective tape along the inside and outside edges of the body. Using an awl, make a hole through the adhesive from inside the vehicle. Push a piece of piano wire through the hole, and wrap each end around a piece of wood.




5. With a helper on the outside, pull the piano wire (A) back and forth in a sawing motion. Hold the piano wire as close to the quarter glass (B) as possible to prevent damage to the body, and carefully cut through the adhesive (C) around the entire quarter glass.
6. Carefully remove the quarter glass.
7. With a putty knife, scrape the old adhesive smooth to a thickness of about 2 mm (0.08 in.) on the bonding surface around the entire quarter glass opening flange:
- Do not scrape down to the painted surface of the body; damaged paint will interfere with proper bonding.
- Remove the fasteners from the body.

8. Clean the body bonding surface with a sponge dampened in alcohol. After cleaning, keep oil, grease, and water from getting on the surface.
9. If the old quarter glass is to be reinstalled, use a putty knife to scrape off all of the old adhesive and the rubber dam from the glass. Clean the inside face and the edge of the glass with alcohol where new adhesive is to be applied. Make sure the bonding surface is kept free of water, oil, and grease.




10. Glue the fasteners (A) and rubber dam (B) to the inside surface of the glass (C) as shown:
- Be sure the center of the fasteners line up with the alignment dots (D).
- Be sure both ends of the rubber dam line up with the alignment marks (E).
- Be careful not to touch the glass where adhesive will be applied.




11. Glue the fasteners (A) to the body as shown.




12. Set the quarter glass (A) in the opening, and center it. While you are holding the quarter glass on the outside, have an assistant make alignment marks on the glass with a grease pencil through the body holes (B) from inside the vehicle. Be careful not to touch the quarter glass where adhesive will be applied.
13. Remove the quarter glass.




14. Align the center of the clips (A) with the alignment makes you made in step 12, and glue them to the inside face of the quarter glass (B) as shown. Be careful not to touch the quarter glass where adhesive will be applied.




15. With a sponge, apply a light coat of glass primer to the edge of the glass (A) and along the rubber dam (B) as shown, then lightly wipe it off with gauze or cheesecloth:
- Do not apply body primer to the quarter glass, and do not get body and glass primer sponges mixed up.
- Never touch the primed surfaces with your hands. If you do, the adhesive may not bond to the quarter glass properly, causing a leak after the quarter glass is installed.
- Keep water, dust, and abrasive materials away from the primed surface.




16. With a sponge, apply a light coat of body primer to the original adhesive remaining around the quarter glass opening flange. Let the body primer dry for at least 10 minutes:
- Do not apply glass primer to the body, and be careful not to mix up glass and body primer sponges.
- Never touch the primed surfaces with your hands.




17. Before filling a cartridge, cut a "V" in the end of the nozzle (A) as shown.




18. Pack adhesive into the cartridge without air pockets to ensure continuous delivery. Put the cartridge in a caulking gun, and run a bead of adhesive (A) around the edge of the glass (B) as shown. Apply the adhesive within 30 minutes after applying the glass primer. Make a slightly thicker bead at each corner.




19. Use suction cups (A) to hold the quarter glass over the opening, align it and set it down on the adhesive. Lightly push on the quarter glass until its edges are fully seated on the adhesive all the way around. Do not open or close the doors until the adhesive is dry.
20. Scrape or wipe the excess adhesive off with a putty knife or towel. To remove adhesive from a painted surface or the rear window, use a soft shop towel dampened with alcohol.
21. Let the adhesive dry for at least 1 hour, then spray water over the sliding door glass and check for leaks. Mark the leaking areas, let the quarter glass dry, then seal with sealant. Let the vehicle stand for at least 4 hours after quarter glass installation. If the vehicle has to be used within the first 4 hours, it must be driven slowly.
22. Reinstall all remaining removed parts. Advise the customer not to do the following things for 2 to 3 days:
- Slam the doors with all the windows rolled up.
- Twist the body excessively (such as when going in and Out of driveways at an angle or driving over rough, uneven roads).