Backlite - Installation

INSTALLATION

CAUTION: To help prevent water leaks, partially roll down the left and right door glass before installing the backlite. This avoids pressurizing the passenger compartment if a door is slammed before the urethane is cured.

CAUTION: Protect all painted and trimmed surfaces from coming in contact with urethane or primers.





1. If the backlite (1) is being reused, remove the as much original urethane (3) as possible from the glass surface using a razor knife (2).






NOTE: To prevent corrosion, do not damage paint on the backlite fence when removing original urethane.

NOTE: The backlite fence should be cleaned of most of its old urethane adhesive. A small amount of old urethane, approximately 1 mm in height should remain on the fence. Do not completely remove all old urethane from the fence, the paint finish and bonding strength will be adversely affected. Replace any missing or damaged spacers around the perimeter of the backlite fence.

2. Using a razor knife (2), level the original bead of urethane (1) on the backlite fence (3) to a thickness of approximately 1 mm (0.04 in.) and remove the loose adhesive.





3. Install a new rubber seal (1) around the top and side edges of backlite (2).
4. Using an assistant, position the backlite into the backlite opening and against the backlite fence (3).
5. Verify the backlite lays evenly against the fence at the top, bottom and sides of the opening. If not, the fence must be formed to the shape of the backlite.
6. Mark the backlite and fence with a grease pencil or pieces of masking tape to use as a reference for installation.
7. Using an assistant, remove the backlite from the backlite opening and place it on a suitable padded work surface.






WARNING: Do not use solvent based glass cleaners to clean the backlite before applying glass prep and primer or poor glass adhesion may result.

8. Clean the inside of the backlite with an ammonia based glass cleaner and a lint-free cloth.
9. Apply glass prep adhesion promoter 25 mm (1 in.) wide (1) around the perimeter of the backlight (2) and 5 mm (0.2 in.) from the edge of the glass and wipe dry with a clean lint-free cloth until no streaks are visible.
10. Apply glass primer 25 mm (1 in.) wide around the perimeter of the backlight and 5 mm (0.2 in.) from the edge of the glass. Allow at least three minutes drying time.
11. Using a flashlight, verify that the primer is completely and evenly installed along the perimeter of the backlite.
12. Re-prime any area that is not fully and evenly primed.





13. Clean the backlite fence with an ammonia based glass cleaner and a lint-free cloth.
14. Apply pinch weld primer 15 mm (0.75 in.) wide (1) around the backlite fence (2). Allow at least three minutes drying time.
15. Using a flashlight, verify that the primer is completely and evenly installed along the backlite fence.
16. Re-prime any area that is not fully and evenly primed.






CAUTION: Always apply the bead of adhesive to the backlite. Always install the backlite within 5 minutes after applying the adhesive.

NOTE: If the original urethane adhesive has been exposed for more than 12 hours, the entire adhesive area will need to be re-primed prior to installing new adhesive.

17. Apply approximately a 10 mm (0.4 in.) wide bead of adhesive (1) with a triangular nozzle approximately 6 mm (0.230 in.) from the edge of the glass (2) starting at the bottom center of the backlite.





18. Run the end of the adhesive bead (1) on the backlite (2) parallel to the start of the bead and smooth the ends flush.





19. Using an assistant, position the backlite (2) over the backlite opening.
20. Using the grease pencil marks or tape as reference points, align the backlite to the opening.
21. Carefully lower the backlite onto the backlite fence (3). Guide the backlite and the rubber seal (1) around the backlite into its proper location.

CAUTION: It is not possible to move the backlite after installation. The backlite should never be pressed into place by more than one person, because the backlite can break if pressed simultaneously on both sides.

22. Push the backlite inward until the backlite comes into contact with the spacers located on each side of the backlite fence.
23. Connect the wire connectors to the rear window defogger terminals and, rear window mounted radio antenna, if equipped.
24. Install the trim panel to the rear shelf Rear Shelf Panel - Installation.