Back Window Glass: Service and Repair

Rear Window Glass (76.81.11)

Special Service Tools






















Removal

1. CAUTION: Make sure the rear window finisher insert is not bent on removal. Failure to follow this instruction may result in damage to the component.

Remove the rear window finisher insert.







2. Remove the rear window finisher.







3. Apply protective tape around rear window glass aperture.







4. Remove the high mounted stoplamp.
5. Remove both C-pillar trim panels.
6. Remove the parcel shelf.

7. NOTE: Right-hand shown, left-hand similar.

Disconnect the electrical connector.







8. Disconnect the radio antenna electrical connector.







9. Apply suitable protective tape to the upper edge of the headlining.







10. Prepare cheese wire and cutting handle.
- Position cutting handle central tube fully upwards in handle.
- Cut a suitable length of cheese wire and pass one end through handle tube and locating aperture.
- Move cutting handle central tube downwards to secure cheese wire.

11. Using a suitable long bladed tool, penetrate the rear window adhesive approximately 150 mm from the top of one rear pillar.







12. Pass free end of cheese wire through penetration and install second cutting handle.







13. WARNING: When removing the rear window glass, personal protection must be worn. Failure to follow this instruction may result in personal injury.

CAUTION:
- Make sure the cheese wire cannot contact the paintwork while the the rear window glass adhesive is being cut. Failure to follow this instruction may result in damage to the vehicle.
- When cutting, do not allow cheese wire to contact edge of window glass as this will crack the window glass.

NOTE: Apply cutting lubricant to the cheese wire frequently through out the cutting process.

With assistance and exercising care to avoid damaging the paintwork, cut around the rear window glass commencing upwards and along the top.







14. Install the lifting handles to the windshield glass, and with assistance carefully remove the rear window glass from the vehicle.







15. Remove the lifting handles from the rear window glass.
16. Remove cheese wire cutting tool from the vehicle, separate handles by moving centre tubes upwards and discard cheese wire.

Installation

1. WARNING:
- If the rear window glass is being installed at a temperature of 23 degrees C (73 degrees F) or above make sure the vehicle is not driven for at least 1 hour after installation.
- If the rear window glass is being installed at a temperature of 11 degrees C (52 degrees F) make sure the vehicle is not driven for at least 1.5 hours after installation.
- If the rear window glass is being installed at a temperature of 5 degrees C (41 degrees F) make sure the vehicle is not driven for at least 2 hours after installation.
- If the rear window glass is being installed at a temperature below 5 degrees C (41 degrees F) use heat and make sure the rear window glass adhesive has set before the vehicle is driven.

NOTE:
- To aid bonding of a new rear window glass, make sure at least 1 mm (0.04 in) of residual adhesive remains on the body flange.
- If the original rear window glass is to be installed remove the residual adhesive from rear window glass mating surface using a suitable scraper.

Using the special tool, remove any residual adhesive from the body.







2. Remove protective tape from around rear window glass aperture.







3. Thoroughly clean rear window glass surface using Betawipe spirit.







4. Apply primer to mating face of rear window glass.







5. Apply glass primer to the mating face of the body flange.







6. Cut the nozzle of the JLM20452 glass bonding adhesive to achieve a triangular section bead 8 mm ( 0.32 in) wide by 10 mm (0.4 in) high.







7. Using the special tool, apply a uniform bead of adhesive to the rear window glass edge, commencing at bottom center and overlapping the ends approximately 14 mm (0.56 in).







8. CAUTION:
- When installing the rear window glass, do not strike it in any way as this will crack the rear window glass.
- Make sure the rear window glass does not move out of position in the rear window glass aperture.

With assistance carefully install the rear window glass into the aperture. Align the rear window glass with the body markings and press firmly into place.







9. Remove the lifting handles.
10. Remove protective tape from rear edge of headlining.

11. CAUTION: Do not connect the electrical connectors for at least 1 hour after installation of the rear window glass. Failure to follow these instructions may result in damage to the rear window glass adhesive.

NOTE: Left-hand shown, right-hand similar.

Connect the electrical connector.







12. CAUTION: Do not connect the electrical connectors for at least 1 hour after installation of the rear window glass. Failure to follow these instructions may result in damage to the rear window glass adhesive.

Connect the radio antenna electrical connector.







13. Install the parcel shelf.
14. Install the C-pillar trim panel.
15. Install the high mounted stoplamp.