Glass - Body Side - Hard Back
Glass - Body Side - Hard Back
Service Repair No - 76.61.29
CAUTION: Always position trim components on a soft covered, clean work surface.
WARNING:
^ Wear protective gloves when handling glass, solvents and primers.
^ Wear suitable eye protection when removing and refitting glass.
The following equipment is required: Cutting wire and handles, Sharp knife, Windscreen repair kit, Sealer applicator gun, Suction cups.
Remove
1. Remove hard-back.
2. Remove 2 screws securing 'E' post finisher, release finisher from clips and remove finisher.
3. Remove 4 Torx screws securing hard-back catches, slide catches from position and remove catches.
4. Remove 3 Torx screws securing headlining release headlining from hard-back seal and remove headlining.
5. Cover interior of hard-back with protective sheet.
6. Apply masking tape to protect paintwork.
7. Make knife cut in sealant at bottom of 'E' post.
8. Insert cutting wire through previously made knife cut and fit handles as shown, with approximately 200 mm of wire between handles.
9. With assistance, wedge tube of handle A between glass and body, ahead of cutting position, and carefully cut sealer using a continuous pull on handle B from the outside. Ensure that glass is retained as last sealant is cut.
If multi-strand cutting wire is used, a sawing action can be used to cut through heavy sealant deposits around corners.
CAUTION: Use of a sawing action may overheat and break single strand wire.
10. Attach suction cup and remove glass body.
CAUTION: Lay glass on felt covered supports. Do not stand on edge. Any chipping of glass edge may develop into cracks.
Refit
1. Carefully remove excess sealer from body leaving a smooth surface.
2. Use a vacuum cleaner to clear away any waste.
3. Original glass: Carefully cut back old sealant to obtain a smooth surface without damaging obscuration band on glass.
4. With assistance, locate glass to body.
5. Apply masking tape reference marks to aid fitment.
6. Remove glass and place aside.
7. Clean frame and edge of glass with solvent.
CAUTION: Do not touch cleaned or primed surfaces with fingers.
8. Repair any damaged paintwork as necessary.
9. Apply bonding agent to glass and allow to cure.
10. Apply activator over old sealer on frame.
11. Allow activator to cure.
12. Apply primer to frame.
13. Fit pre-cut nozzle to sealer cartridge, remove lid and shake out crystals, and install in applicator gun.
Nozzle will need modification to achieve required bead section.
14. Apply a continuous bead of sealer around edge of frame as shown. Make bead slightly thicker at each corner.
15. Check for breaks and air bubbles in sealer.
16. Position glass to body and align to reference tape.
17. Lightly press glass to fully seat sealer.
18. Secure glass with tape until sealer has cured.
19. Remove protective covers and tape.
20. Test seal for leaks, apply additional sealer if necessary. If water is used, allow sealer to dry before testing. Spray water around glass and check for leaks. Dry affected area and apply additional sealer if necessary.
21. Position headlining and locate hardback seal.
22. Secure headlining with Torx screws.
23. Position catches, fit Torx screws and tighten to 10 Nm (7.5 ft. lbs.).
24. Fit 'E post finishers, engage in clips and secure with screws.
25. Fit Hard-back.