Back Window Glass: Service and Repair

REMOVAL
1. Disconnect the battery ground cable.







2. Heat the polyurethane (PU) adhesive if necessary.

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. Remove the rubber weatherseal.







4. Disconnect the heated rear window electrical connectors on each side.
1 Remove the covers.
2 Disconnect the electrical connectors.

NOTE: Position the wires clear of the cutter blade path.







5. Remove the high mount stop lamp cover.
1 Push in the high mount stop lamp cover tabs.
2 Remove the high mount stop lamp cover.







6. Disconnect the high mount stop lamp electrical connector.







7. Cut around the heated rear window glass 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 MAY RESULT IN PERSONAL INJURY.

NOTE: If a heated rear window is to be re-installed, make sure 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 4in cutter blade on the top and the side edges of the heated rear window glass.

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 MAY 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 the heated rear window is to be re-installed, make sure the cutter blade is kept low when cutting in the area of the heated rear window connectors.







9. Cut the bottom edge of the heated rear window glass using Interior Auto Glass Cut-Out Knife No. 164-R2450 fitted with the 8in cutter blade.







10. With the aid of another technician, use suction cups to remove the heated rear window glass.

INSTALLATION

CAUTION:
^ During the curing period of the PU adhesive, the door windows must be left open to avoid a build up of pressure when the doors are opened and closed.

^ Avoid touching the trimmed surfaces as this will inhibit the new adhesive from bonding.







1. Remove the excess PU adhesive from the opening.
^ Carefully trim the remaining PU adhesive from the rear window opening to leave approximately 1 mm of trimmed PU adhesive adhered to the opening flange.

2. Check the pinch weld sealing area for damaged sheet metal, rust or foreign objects which may have caused, or may cause glass breakage.







3. Using a hot air gun, apply warm air (25°C) to the rear window opening flange and glass bond line to remove all traces of moisture.

CAUTION: To make sure that the PU adhesive cures, it is essential that all the bonding surfaces are free of moisture.







4. Prepare the glass, windshield opening 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 rear window opening flange along the bond line.

NOTE: Discard the 100 mm (4in) of PU adhesive as this may have a reduced working time.







6. Install the rubber weatherseal.







7. With the aid of another technician, use suction cups to install the heated rear window glass.

NOTE: Firmly and evenly press in position.







8. 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).







9. Connect the high mount stop lamp electrical connectors.







10. Install the high mount stop lamp cover.
1 Push in the high mount stop lamp cover tabs.
2 Install the high mount stop lamp cover.







11. Connect the heated rear window electrical connectors on both sides.
1 Connect the heated rear window electrical connectors.
2 Install the heated rear window electrical connector covers.

12. Connect the battery ground cable.