Back Window Glass: Service and Repair

REAR WINDOW GLASS

Rear Window Glass:

REMOVAL

1. To remove the rear window glass, first remove the following parts:
- Rear seat cushion
- Rear seat-back
- Rear package tray trim
- Rear pillar trim
- Rear window lower cover molding
- Root assist handle

CAUTION:
- Wear gloves to remove and install the rear window.
- Use seat covers to avoid damaging any surfaces.
- Do not damage the rear window defogger grid lines, window antenna grid lines, and terminals.

2. Disconnect the rear window defogger connector and window antenna connector.
3. Remove the rear window glass molding.

NOTE: When molding removal is difficult, cut the molding with a knife.






4. Pull down the rear of the headliner.
5. In order to protect the body (paint surface), apply cloth tape around to body flange the installed rear window glass.
6. Use the special tool (09861 - 31100) to cut through the sealant.






7. Make mating marks on the glass and body if the glass is to be reinstalled.

NOTE: Use chalk or equivalent to make mating marks on the glass and body

8. Take out the windshield glass with the special tool, glass holder.






9. Check the body flange for deformation.

INSTALLATION

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

NOTE:
- Do not scrape down to the painted surface of the body space; damaged paint will interfere with proper bonding.
- Mask off surrounding surfaces before painting.
- Remove the clips from the body.






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

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

3. Install the rear window lower molding mounting clips and rear window lower spacers.






4. If the old rear window is to be reinstalled, use a putty knife to scrape off all traces of old adhesive and the rubber dam, 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.

5. Set the rear window, then center it in the opening. Make alignment marks across the rear window and body with a grease pencil at the four points shown.






6. Evenly apply a light coat of glass primer to the rear window glass and then let it dry for 1 to 15 minutes.

NOTE:
- Do not apply body primer to the glass.
- The primer strengthens the adhesive, so be sure to apply it evenly around the entire circumference.
Also, a too thick application will weaken the adhesive.
- Never touch the primed surface with your hand. If you do, the adhesive may not bond to the glass properly, causing a leak after the rear window is installed.
- Keep water, dust, and abrasive materials away from primed surface.






7. Glue the rubber dam to the inside surface of the rear window glass around the entire edge as shown, to contain the sealant during installation.






8. Install the molding around the edge of the rear window as shown.






9. Apply the light coat of body primer to the original sealant remaining around the body flange. The glass should be installed 10 minutes after you apply the primer.






10. Pack adhesive into the cartridge without air packets, to ensure continuous application. Put the cartridge in a caulking gun or sealant gun, and run a bead of adhesive around the edge of the glass as shown.

NOTE: Apply the adhesive within 5 minutes after applying the glass primer.






11. Using the suction cups, or the special tool (09861-31400), hold the rear window over the opening to align it with the alignment marks and set it down on the adhesive. Lightly push on the rear window until its edges carefully seated on the adhesive all the way around.

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






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

NOTE: To remove adhesive from a painted surface or the rear window, use a soft shop towel dampened with alcohol.

13. Let the adhesive dry for at least one hour, then spray water over the rear window and check for leaks. If there are leaks, dry the affected area, then apply sealant.

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

14. Install the removed parts.

NOTE:
Advise the customer not to do the following things for two to three 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).