Windshield Glass - Rear Window
REMOVAL1. Disconnect the battery ground cable.
2. Heat the adhesive if required.
NOTE: Should the ambient temperature fall below 10°C heat the cartridges for approximately 15 minutes by placing them on a warm radiator, or by using a hot air gun set at approximately 25°C.
3. Pull out the rubber weatherseal.
4. Disconnect the heated rear window electrical connector.
1 Remove the covers.
2 Disconnect the electrical connector.
NOTE: Position the wires clear of the cutter blade path.
5. Detach the high mount stop lamp.
1 Push in the lamp cover tabs.
2 Remove the stop lamp cover.
6. Disconnect the stop mount electrical connector.
7. Cut around the rear window using the Oscillating Cutter No.107-R1511 fitted with a 24 mm hooked blade.
WARNING: Wear gloves and eye protection when working with the glass cutting tool as the cutting operation may produce splinters. When using the cutter wear ear protection. Failure to follow these instructions will result in personal injury.
NOTE: If a rear window is to be re-installed, ensure the cutter blade is kept low when cutting in the area of the heated rear window connectors.
8. Use Interior Auto Glass Cut-Out Knife No. 164-R2450 or equivalent to cut out the PU adhesive, using the 4 in cutter blade on the top and the side edges of the windshield.
WARNING: Wear gloves and eye protection when working with the glass cutting tool as the cutting operation may produce splinters. When using the cutter wear ear protection. Failure to follow these instructions will result in personal injury.
NOTE:
^ Lubricate the PU adhesive where it meets the glass with EC7784 lubricant or equivalent (10:1 ratio of water to soap) to aid Interior Auto Glass Cut-Out Knife Kit, when cutting the PU adhesive.
^ If a rear window is to be re-installed, ensure the cutter blade is kept low when cutting in the area of the heated rear window connectors.
9. Cut the bottom edge of the windshield using Interior Auto Glass Cut-Out Knife No. 164-R2450 fitted with the 8 in cutter blade.
10. Remove the window.
NOTE: Use the aid of another technician and using suction cups, remove the window.
INSTALLATION
1. Remove the excess PU adhesive from the aperture using a utility knife.
^ Carefully trim the remaining PU adhesive from the windshield aperture to leave approximately 1 mm of trimmed PU adhered to the bodywork.
^ Check the pinch weld sealing area for damaged sheet metal, rust or foreign objects which may have caused, or may cause, glass breakage.
CAUTION: Avoid touching the trimmed surface as this will inhibit the new adhesive from bonding.
2. If the original windshield is to be re-installed, remove the excess PU adhesive from the glass.
3. Using a hot air gun, apply warm air (25°C) to the window opening and glass bond line to remove all traces of moisture.
NOTE: To ensure that the PU adhesive cures, it is essential that all bonding surfaces are free of all moisture.
4. Prepare the glass, window aperture and trimmed PU adhesive in accordance with the instructions supplied with the adhesive kit.
5. Apply the PU adhesive in a continuous bead of between 8 and 10 mm height to the window flange along the bond line.
NOTE:
^ Discard the first 10 cm (4 in) of PU adhesive as this may have a reduced working time.
^ To avoid water leaks, any breakage in the continuous bead should be overlapped by 20 mm (0.75 in).
6. Install the window.
^ Firmly and evenly press into position.
NOTE: Use the aid of another technician and using suction cups, remove the window.
7. Should the ambient temperature fall below 10°C, use a hot air gun at a distance of approximately 5 cm from the substrate and apply warm air (25°C) continuously for 15 minutes (inside or outside the vehicle).
8. To install, reverse the removal procedure.