Diesel Data: Automotive Repair
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3D

Removal

CAUTION:
- Put on gloves to protect your hands.
- Use seat covers to avoid damaging any surfaces.

1. To remove the quarter glass, first remove the:
- Rear seat-back and rear seat cushion
- Rear center shelf and rear side shelf
- Rear trim panel and side trim panel
- Upper anchor bolts from the front and rear seat belts
- Quarter trim panel




Upper Portion/Lower Portion/Pillar Portion:




2. From inside the car, use a knife to cut through the quarter glass adhesive all the way around.

NOTE:
- If the clip on the rear edge is broken, the quarter glass can be reinstalled using butyl tape .
- Apply protective tape along the edge of the entire quarter glass opening flange.

3. Carefully remove the quarter glass.

NOTE: Check the quarter glass trim and clips for damage, and replace them if necessary.

Installation

1. Using a knife, scrape the old adhesive smooth to a thickness of about 2 mm (0.08 in.) on the bonding surface around the entire quarter glass opening flange.

NOTE:
- Do not scrape down to the painted surface of the body; damaged paint will interfere with proper bonding.
- Remove the rubber dams from the body.
- If any of the clips are broken, remove them from the body.
- Mask off surrounding surfaces before applying primer.

2. Clean the body bonding surface with a sponge dampened in alcohol.

NOTE: After cleaning, keep oil, grease and water from getting on the surface.




3. If the quarter glass is to be reinstalled, use a putty knife to scrape off all traces of old adhesive, then clean the quarter glass surface with alcohol where adhesive is to be applied.

NOTE: Make sure the bonding surface is kept free of water, oil and grease.

CAUTION: Avoid setting the quarter glass on its edges: small chips may later develop into cracks.

NOTE: Clean the shadowed area.




4. Glue the upper and lower rubber dams to the inside face of the quarter glass, as shown, to contain the adhesive during installation.

NOTE: Be careful not to touch the quarter glass where adhesive will be applied.




5. Install the quarter glass trim on the quarter glass, then glue the upper and lower clips as shown.

NOTE: Be careful not to touch the quarter glass where adhesive will be applied.




6. If the old quarter glass is to be reinstalled (and the clip on the rear edge is broken off), apply a light coat of primer (3M C-100, or equivalent), then apply butyl tape to the quarter glass, as shown, and seal the body hole with piece of urethane tape.

NOTE:
- Be careful not to touch the quarter glass where adhesive will be applied.
- Do not peel the separator off the butyl tape.




7. With a sponge, apply a light coat of glass primer to the inside face of the quarter glass, as shown, then lightly wipe it off with gauze or cheesecloth.

NOTE:
- Do not apply body primer to the quarter glass, and do not get body and glass primer sponges mixed up.
- Never touch the primed surfaces with your hands. If you do, the adhesive may not bond to the quarter glass properly, causing a leak after the quarter glass is installed.
- Keep water, dust, and abrasive materials away from the primed surface.




8. With a sponge, apply a light coat of body primer to the original adhesive remaining around the quarter glass opening flange. Let the body primer dry for at least 10 minutes.

NOTE:
- Do not apply glass primer to the body, and be careful not to mix up glass and body primer sponges.
- Never touch the primed surfaces with your hands.
- Mask off the rear side trim panel before painting the flange.

9. Thoroughly mix the adhesive and hardener together on a glass or metal plate with a putty knife.

NOTE:
- Clean the plate with a sponge and alcohol before mixing.
- Follow the instructions that came with the adhesive.




10. Before filling a cartridge, cut the end of the nozzle as shown.




11. Pack adhesive into the cartridge without air pockets to ensure continuous delivery. Put the cartridge in a caulking gun, and run a bead of adhesive around the edge of the quarter glass as shown.

NOTE:
- If the old quarter glass is to be reinstalled, peel the separator off the butyl tape after applying the adhesive.
- Apply the adhesive within 30 minutes after applying the glass primer.




12. Use suction cups to hold the quarter glass over the opening, align the clips, and set it down on the adhesive. Lightly push on the quarter glass until its edges are fully seated on the adhesive all the way around.

NOTE: Do not open or close the doors until the adhesive is dry.

13. Scrape or wipe the excess adhesive off with a putty knife or towel.

NOTE: To remove adhesive from a painted surface or the quarter glass, wipe with a soft shop towel dampened with alcohol.

14. Let the adhesive dry for at least one hour, then spray water over the quarter glass and check for leaks. Mark the leaking areas, let the quarter glass dry, then seal with sealant.

NOTE: Let the car stand for at least four hours after quarter glass installation. If the car has to be used within the first four hours, it must be driven slowly.

15. Reinstall all remaining removed parts.

NOTE: Advise the customer not to do the following things for two to three days:
- Slam the doors with all the windows rolled up.
- Twist the body excessively (such as when going in and out of driveways at an angle or driving over rough, uneven roads).
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