Glass - Body Side - Rear

Glass - Body Side - Rear

Service Repair No - 76.81.18

The following equipment is required: Cutting wire and handles Windscreen repair kit, Sealer applicator gun, Suction cups.

WARNING:
^ Wear protective gloves when handling glass, solvents and primers.
^ Wear suitable eye protection when removing and refitting glass.

Remove

1. Remove rear quarter upper casing.
2. Cover interior of vehicle with protective sheet.





3. Make knife cut in sealant at bottom of 'D' post.
4. Insert cutting wire through previously made knife cut and fit handles as shown, with approximately 200 mm of wire between handles.
5. With assistance, wedge tube of handle B between glass and body, ahead of cutting position, and carefully cut sealer using a continuous pull on handle A 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.

6. 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.

7. Collect 4 spacer blocks.

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 sealer to obtain a smooth surface without damaging obscuration band on glass.
4. Fit rubber spacer blocks to body.
5. With assistance, locate screen to body.
6. Apply masking tape reference marks to aid fitment.
7. Remove screen and place aside.
8. Clean frame and edge of screen with solvent.

CAUTION: Do not touch cleaned or primed surfaces with fingers.

9. Apply etch primer to any bare metal on frame.
10. Apply bonding agent to screen and allow to cure.
11. Apply primer over etch primer on frame.
12. Apply activator over old sealer on frame.
13. Allow activator to cure.
14. Fit pre-cut nozzle to sealer cartridge, remove lid and shake out crystals. Install cartridge in applicator gun.
Nozzle will need modification to achieve required bead section.





15. Apply a continuous bead of sealer around edge of frame as shown. Make bead slightly thicker at each corner.
16. Check for breaks and air bubbles in sealer.
17. Position glass to body and align to reference tape.
18. Lightly press glass to fully seat sealer.
19. Secure glass with tape until sealer has cured.
20. Remove protective covers and tape.
21. Test sealer 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. Mark leakage points and apply additional sealer as necessary when area is completely dry.
22. Fit rear quarter upper casing.