Back Window Glass: Service and Repair
Rear WindowRemoval
CAUTION: Wear gloves to remove and install the rear window.
1. To remove the rear window, first remove these items:
- 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. From outside the vehicle, use a knife to cut the upper and lower moldings all the way around. Cut the outer rubber portion (1) off the molding first, then cut the top rubber portion (2).
CAUTION: Take care not to scratch or score the rear window and body.
6. Apply protective tape along the edge of the body.
7. Using an awl, make a hole through the adhesive from inside the vehicle. 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. With 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 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. Install the rear defogger sub-harness and ground cable/antenna lead in the upper molding.
4. Set the rear window upright on the body, then center it in the opening. Make alignment marks across the rear window and body with a grease pencil at the four points shown.
5. 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.
- Keep water, dust, and abrasive materials away from the primed surface.
6. 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.
7. 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.
8. Before filling a cartridge, cut the end of the nozzle as shown.
9. Pack adhesive into the cartridge without air pockets to ensure continuous delivery. Put the cartridge in a caulking 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.
10. Use suction cups to hold the rear window over the opening, align it with the alignment marks made in step 4, 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.
11. 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 vehicle stand for at least four hours after rear window installation. If the vehicle has to be used within the first four hours, it must be driven slowly.
12. Connect the rear defogger sub-harness and ground cable/antenna lead, then install the grommets.
13. Reinstall all remaining removed parts.