Liftgate Window Glass: Service and Repair

General Equipment
^ Hot air gun
^ Pneumatic knife with offset blade
^ Interior auto glass cut-out knife kit

REMOVAL







1. 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.

2. Remove the liftgate interior trim panel.







3. Disconnect the rear window electrical connectors.







4. Remove the rear window wiper.







5. Remove the rear window weatherstrips.







6. Cut around the rear window using the pneumatic knife 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 PROTECTORS. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.

NOTE: If the same 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.







7. Use the interior auto glass cut out knife to cut out the PU adhesive, using the four inch cutter 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 PROTECTORS. 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 same 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. Using suction pads and with the aid of another technician remove the rear window.

INSTALLATION







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

CAUTION: Avoid touching the trimmed surface as this will inhibit the new adhesive from bonding.

NOTE: If the original rear window is to be installed, remove the excess PU adhesive from the glass as described in this step.

2. Check the pinch weld sealing area for damaged sheet metal. rust or foreign material 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 and glass bond line to remove all traces of moisture.

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

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

NOTE:
^ Discard the first 100 mm of PU adhesive as this may have a reduced working time.
^ To avoid water leaks, any breakage in the continuous head should be overlapped by 20 mm.







6. Using suction pads and with the aid of another technician install the rear window.

NOTE: Firmly and evenly press in position.







7. Should the ambient temperature fall below 10°C, use a hot air gun at a distance of approximately 50 mm from the opening and apply warm air (25°C) continuously for 15 minutes (inside or outside the vehicle).







8. Install the rear window wiper.







9. Connect the rear window electrical connectors.
10. Install the rear interior trim panel.







11. Install the rear window weatherstrips.