Back Window Glass: Service and Repair

Rear Window

Removal

CAUTION:
- Wear gloves to remove and install the rear window.
- Since the rear window is double glazed glass with the inner glass (interior-side) larger than the outer glass, care should be taken not to damage the edge of the inner glass when removing the outer glass.

1. To remove the rear window, first remove:
- Seats
- Center pillar trim panel
- Rear upper trim panel
- Rear hatch assembly

2. Remove the weatherstrip.




3. Disconnect the rear defogger sub-harness and ground cable/antenna lead, then remove the grommets.




4. Remove the rear defogger sub-harness and ground cable/antenna lead from the upper molding.
5. Use a knife to cut the upper and lower moldings from outside the car, all the way around.






CAUTION: Take care not to scratch or score the rear window and body.

NOTE: Cut the outer side rubber portion (1) off the molding, then cut the top rubber portion (2).

6. Apply protective tape along the edge of the body.
7. Using an awl, make a hole through the adhesive from inside the car. Push piano wire through the hole, and wrap each end around a piece of wood.
8. Pull the piano wire back and forth in a sawing motion, and carefully cut through the adhesive around the entire rear window.






CAUTION: Hold the piano wire as close to the rear window as possible to prevent damage to the body.

Installation

1. Scrape old adhesive smooth with a knife to a thickness of about 2 mm (0.08 in.) on the bonding surface around the entire rear window flange.

NOTE:
- Do not scrape down to the painted surface of the body; damaged paint will interfere with proper bonding.
- Mask off surrounding surfaces before applying primer.

2. Clean the body bonding surface with a sponge dampened in alcohol.

NOTE: After cleaning, keep oil, grease or water from getting on the surface.

3. If the old rear window is to be reinstalled, use a putty knife to scrape off all traces of old adhesive, then clean the rear window surface with alcohol where new adhesive is to be applied.

NOTE: Make sure the bonding surface is kept free of water, oil and grease.






CAUTION: Avoid setting the rear window on its edges; small chips may later develop into cracks.

NOTE: Be careful not to cut the adhesive and rubber dam between the inner glass and outer glass.

4. Clean the rear window surface with alcohol where the new moldings are to be installed.

NOTE: Make sure the surface is kept free of water, oil and grease.

5. With a brush, apply a light coat of glass primer around the edge of the rear window.






NOTE: Scrape off excess glass primer with a putty knife after installing the new moldings.

6. Degrease the inner surfaces of the new upper and lower moldings thoroughly then apply a light coat of glass primer to the surfaces.






NOTE:
- Apply glass primer around the entire groove of the new upper and lower moldings.
- Do not apply glass primer to the outer surface.




7. Run a bead of adhesive in the upper and lower molding grooves.
8. Press the upper and lower moldings into position around the entire edge of the rear window.






NOTE: Check that the upper and lower moldings are not wrinkled or lifted away at the corners.

9. Scrape or wipe the excess adhesive off with a putty knife or towel.

NOTE: Use a soft shop towel dampened with alcohol to remove adhesive from the rear window or upper and lower moldings.




10. After the adhesive is dry, install the rear defogger sub-harness and ground cable/antenna lead in the upper molding.




11. Set the rear window upright on the body, then center it in the opening. Make alignment marks by marking lines across the rear window and body with a grease pencil at the four points shown.
12. Glue the upper and lower rubber dams to the inside face of the rear window, as shown, to contain the adhesive during installation.






NOTE: Be careful not to touch the inner glass where adhesive will be applied.

13. With a sponge, apply a light coat of glass primer around the edge of the rear window as shown, then lightly wipe it off with gauze or cheesecloth.






NOTE:
- Do not apply body primer to the rear window, 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 inner glass properly, causing a leak after the rear window is installed.
- Keep water, dust, and abrasive materials away from the primed surface.

14. With a sponge, apply a light coat of body primer to the original adhesive remaining around the rear window opening flange.






NOTE:
- Do not apply body primer to the rear window, and do not get body and glass primer sponges mixed up.
- Never touch the primed surfaces with your hands.

15. Thoroughly mix the adhesive and hardener together on a glass or metal plate with a putty knife.

NOTE:
- Clean the plate with a sponge and alcohol before mixing
- Follow the instructions that came with the adhesive.




16. Before filling a cartridge, cut the end of the nozzle as shown.
17. Pack adhesive into the cartridge without air pockets to ensure continuous delivery. Put the cartridge in a calking gun, and run a bead of adhesive around the edge of the rear window as shown.






NOTE: Apply the adhesive within thirty minutes after applying the glass primer.

18. Use suction cups to hold the rear window over the opening, align it with the alignment marks made in step ii and set it down on the adhesive. Lightly push on the rear window until its edges are fully seated on the adhesive all the way around.






NOTE: Do not close or open the doors until the adhesive is dry.

19. After the adhesive is dry, spray water over the rear window and check for leaks. Mark leaking areas and let the rear window dry, then seal with sealant.

NOTE: Let the car stand for at least four hours after rear window installation. If the car has to be used within the first four hours, it must be driven slowly.

20. Connect the rear defogger sub-harness and ground cable/antenna lead, then install the grommets.
21. Reinstall all remaining removed parts.