Rear Window Glass

REAR WINDOW GLASS

REMOVAL

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.

1. To remove the rear window, first remove the following parts :
1. Rear Seat Cushion
2. Rear Seat-back
3. Rear Package tray trim
4. Rear pillar trim
5. Rear Window Lower cover molding
6. Roof assist handle

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






6. 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.






7. Take out the windshield glass with the special tool (09861-31400).






INSTALLATION

1. Using a knife or the special tool (09861-31200), cut the old sealant smoothly to a thickness of about 2 mm (0.08 in.) on the bonding surface around the entire rear window glass.

CAUTION: Be careful not to remove more adhesive than necessary, and also not to damage the paintwork on the body surface with the knife. If the paintwork is damaged, repair the damaged area with touch-up-paint.






2. Clean the body bonding surface with a sponge dampened in alcohol, or wax and grease remover.
3. Install the rear window lower molding mounting clip and rear window lower spacer.






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:
1. Do not apply body primer to the glass.
2. 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.

3. 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.
4. Keep water, dust, and abrasive materials away from the primer.

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






10. Pack adhesive into the cartridge avoiding air pockets, 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.






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

Using the suction cups or the special tool (09861-31400), lower the glass over the opening to align it with the marks made in step 5 and set it down on the sealant. Insert two lower spacers to prevent the rear window from moving downward.






11. Use suction cups or the special tool (09861-31400) to hold the rear window over the opening, align it with the alignment marks 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 open or close the doors until the adhesive is dry.

12. Remove excess adhesive with a putty knife or gauze. Fill any cavities around the rear window glass.
13. After one hour, perform a water-leak test for the windshield. Use a cold water spray, being careful not to direct a powerful stream of water on the new adhesive material. Allow water to spill over the edges of the glass.






14. If there are leaks, dry the affected area, then apply sealant.

NOTE:
- Let the car stand for at least four hours after windshield installation. If the car has to be used within the first 8 hours, it must be driven slowly.
- Keep the windshield dry for the first hour after installation.

15. Install the removed parts.

NOTE: Advise the customer not to do the following for two to three days:
- Slam the doors with all the windows rolled up.
- Stress the body excessively (such as when going in and out of driveways at an angle or driving over rough, uneven roads).