Hatchback

Removal

Hatchback

CAUTION:
- Use covers to avoid damaging the interior.
- Wear gloves to remove and install the glass.
- Do not damage the defroster grid lines.
- Take care not scratch the rear window molding.

1. To remove the rear window, first remove the:
- Rear shelf
- Hatch side trim and hatch trim panel
- High mount brake light
- Rear window wiper arm and rear window wiper motor




2. Remove the rear window trim, and disconnect the connectors.




3. Apply protective tape to the inner and outer edges of the hatch.
Using an awl, make a hole through the adhesive from the inside, at the top of the hatch. Push piano wire through the hole, and wrap each end around a piece of wood.
4. With a helper on the outside, pull the piano wire back and forth in a sawing motion, and carefully cut through the adhesive along the too and the sides of the rear window.






CAUTION: Hold the piano wire as close to the rear window as possible to prevent damage to the body and molding.

5. Cut the adhesive with a knife at the bottom of the rear window.

NOTE: Do not use piano wire in this area.

6. Carefully remove the rear window.






NOTE: Replace the fasteners with new ones whenever the rear window has been removed.

Installation

1. Scrape the old adhesive smooth with a knife to a thickness of about 2 mm (0.08 in) on the bonding surface around the entire rear window opening flange.

NOTE:
- Do not scrape down to the painted surface of the body; damaged paint will interfere with proper bonding.
- Remove the upper and lower fasteners from the hatch.
- Mask off surrounding surfaces before applying primer.

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

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

3. If the old rear window is to be reinstalled, use a putty knife to scrape off all traces of old adhesive, 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; the molding can be permanently deformed.

NOTE: Clean the shadowed area.

4. Apply the upper seal to the inside face of glass as shown.




5. Glue the upper fasteners, lower fasteners and side spacers, to the inside face of the rear window on each side.




6. Glue the lower fasteners and upper fasteners to the hatch as shown.




7. Set the rear window upright on the hatch, then center it in the opening. Make alignment marks across the rear window and body with a grease pencil at the four points shown.
8. Remove the rear window.
9. Center and glue the side rubber dams to the inside face of the rear window, as shown, to contain the adhesive during installation.






NOTE:
- Glue the side rubber dams, using the printed dots as a guide.
- Be careful not to touch the rear window where adhesive will be applied.
- Mask off surrounding surfaces before applying primer.




10. Install the rear window trim.
11. With a sponge, apply a light coat of glass primer around the edge of the rear window, 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. If you do, the adhesive may not bond to the rear window properly, causing a leak after the rear window is installed.
- Keep water, dust, and abrasive materials away from the primed surface.

12. With a sponge, apply a light coat of body primer to the original adhesive remaining around the rear window opening flange. Let the body primer dry for at least 10 minutes.






NOTE:
- Do not apply glass primer to the body, and be careful not to mix up glass and body primer sponges.
- Never touch the primed surfaces with your hands.

13. 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.




14. Before filling a cartridge, cut the end of the nozzle as shown.




15. 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.
16. Use suction cups to hold the rear window over the opening, align it with the alignment marks made in step 7, 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.

17. 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.

18. Let the adhesive dry for at least one hour, then 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 car stand form at least four hours after rear window installation. If the car has to be used within the first four hours, it must be driven slowly.

19. Reinstall all remaining 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).