Back Window Glass: Service and Repair
REAR WINDOW GLASS - 4-DOORSpecial Tool(s):
SPECIAL TOOL(S)
REMOVAL
WARNING: To prevent glass splinters from entering the eyes or cutting the hands, wear safety glasses and heavy gloves when cutting the glass from the vehicle.
1. Position the parcel shelf aside.
1 Release the backrest latch trim panels.
2 Remove the left-hand safety belt trim panel.
3 Move the parcel shelf forward.
2. Remove the C-pillar trim panel.
3. Release the rear of the headliner from the roof panel.
- Remove the pin-type retainers.
4. Place 2 blocks of suitable material between the headliner and the roof panel to act as spacers.
5. Disconnect the heated rear window electrical connectors.
6. Remove the screws and position the high mounted stoplamp aside.
7. Disconnect the electrical connector and remove the high mounted stoplamp.
8. CAUTION: Make sure the cutting blades are changed where the cutting depth changes to avoid damage to the body and trim panels.
NOTE:
- Some resistance may be encountered when cutting through the glass locating pegs in the bottom corners of the glass.
- Lubricate the urethane adhesive with water to aid the special tool when cutting the urethane adhesive.
Using the special tool, place the flat side of the knife against the rear glass. Start at the top center and work out and down the pillars to the lower corners cutting to the given maximum depths:
1 30 mm
2 25 mm
INSTALLATION
CAUTION: When installing urethane installed glass parts, the vehicle must not be driven until the urethane adhesive has cured. At temperatures above 21°C (70°F) and relative humidities above 50%, adequate cure time is typically 24 hours. (Refer to Essex drive away chart for the cure times as temperatures and humidity vary.) Inadequate or incorrect curing can adversely affect the retention of the rear window glass.
1. Dry fit the rear window glass to the existing urethane adhesive on the body pinch weld. Align the glass in the opening for a uniform fit.
2. Use a non-premanent pencil to make alignment marks to aid in the installation alignment of the rear window glass.
3. Remove the rear window glass.
4. NOTE: Avoid scratching the pinch weld area.
Trim the remaining urethane adhesive on the pinch weld. The urethane adhesive must be smooth and free of cuts and contamination after trimming. Avoid touching the urethane adhesive after preparation.
5. Apply urethane metal primer to any exposed or damaged metal on the pinch weld.
6. If installing the original rear window glass, remove the excess urethane adhesive.
7. Clean the rear window glass with a non-alcohol based window cleaner.
8. CAUTION: Wipe off the urethane glass prep immediately after each application because it flash dries.
If installing a new rear window glass, apply urethane glass prep twice to the area to be urethaned.
9. If installing a new rear window glass, apply urethane glass primer to the same area that was prepped in the previous step. Allow 5 minutes to dry.
10. Cut the urethane adhesive applicator tip to specification.
11. Apply a bead of urethane adhesive on top of the existing urethane bead on the pinch weld. Make sure that all gaps in the urethane adhesive are smoothed into one continuous bead.
12. Install the rear window glass on the pinch weld. Align the rear window glass to the body using the alignment marks.
13. Inspect the rear window glass for air or water leaks through the urethane adhesive seal.
14. Connect the high mounted stoplamp electrical connector.
15. Install the high mounted stoplamp.
16. Position the headliner and install the pin-type retainers.
- Remove the spacers.
17. Connect the heated rear window electrical connectors.
18. Install the C-pillar trim panel.
19. Install the rear parcel shelf.
1 Position the parcel shelf.
2 Install the left-hand safety belt trim panel.
3 Attach the backrest latch trim panels.