Rear Window Glass - Vehicles Without: Convertible Top

Rear Window Glass - Vehicles Without: Convertible Top (76.81.11)

Removal

1. Remove battery cover and disconnect ground cable from battery terminal.
2. Using masking tape, mark top and bottom central positions of finisher on BIW.







3. Remove backlight finisher.
4. Remove rear seat cushion and squab.
5. Remove coat hanger hook.
6. Remove rear quarter casing.
7. Remove rear sub-woofer speaker cover.
8. Remove rear parcel shelf.
9. Disconnect backlight heater connectors.







10. Disconnect alarm aerial connector from centre of backlight.







11. If high level stop lamp is fitted, withdraw lamp cover from two clips on base assembly.







12. Disconnect and remove high level stop lamp.
- Disconnect harness connector from lamp.
- Lift lamp assembly clear of two retainers on backlight and remove lamp from vehicle.







13. Apply protective masking tape around backlight aperture.







14. Use masking tape to mark the positions of the eighteen finisher securing clips then remove clips from glass.







15. If original backlight is to be re-fitted, mark top and bottom central positions with masking tape to aid re-positioning.







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

17. Using a suitable long bladed tool, penetrate backlight Betaseal at lower central position.







18. Remove tool, pass free end of cheese wire through penetration and fit second cutting handle.







19. With assistance, use the cheese wire to cut around the backlight glass exercising particular care at the corners to avoid damage to paint







20. Fit lifting handles to glass, carefully remove backlight from vehicle and place on clean cloth on bench.







21. Remove lifting handles from backlight glass.
22. Remove cheese wire cutting tool from vehicle, separate handles by moving centre tubes upwards and discard cheese wire.
23. Apply protective tape to glass aperture flange.







24. Apply protective tape to rear edge of headlining.







25. Place protective sheet over parcel tray area.
26. Exercising care not to damage paintwork, use vibroknife to remove residual sealant from body flange.







27. Remove protective tape from glass aperture flange.

Installation

1. If original backlight is to be refitted, remove residual sealant from glass mating surface using a suitable scraper.







2. Thoroughly clean mating surface using Betawipe spirit and fit finisher securing clips at positions marked by masking tape.







3. To prevent sealant ingress into clips causing difficulty in subsequent removal of finisher apply masking tape to back of finisher.







4. Fit and fully seat finisher onto clips.







5. If backlight is being renewed, fit lifting handles to glass, with assistance position it correctly in aperture and using masking tape, mark top and bottom central positions on glass and BIW.







6. Remove glass from vehicle, position on bench and remove lifting handles.
7. Clean glass mating edge and body aperture flange using Betawipe spirit.
8. Apply glass primer to mating area of glass.







9. Cut Betaseal nozzle to achieve a triangular section bead 8 mm wide by 10 mm high.







10. Using a suitable pneumatic application gun, apply a uniform bead of sealant to the glass edge commencing at bottom center and overlapping the ends approximately 100 mm.







11. Fit lifting handles and with assistance, carefully align glass with body markings and press firmly into place.







12. Remove lifting handles.
13. Remove tape markers from glass.
14. Aligning central joints with tape markers on BIW, fit finisher to backlight.
15. Remove tape markers from BIW.
16. Remove protective sheet from rear parcel shelf area.
17. Remove protective tape from rear edge of headlining.
18. Connect alarm aerial and backlight connectors.
19. Fit and fully seat high level stop lamp on backlight retainers.
20. Fit harness connector to high level stop lamp and fit and fully seat cover onto lamp retaining clips.
21. Fit rear parcel shelf.
22. Fit sub-woofer speaker and cover.
23. Fit rear quarter casings.
24. Fit rear coat hanger hook.
25. Fit rear seat squab and cushion.
26. Connect ground cable to battery terminal and fit battery cover.
27. Thoroughly clean backlight and surrounding area.