Diesel Data: Automotive Repair
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Back Window Glass: Service and Repair

Back Window Glass (Coupe):






REPLACEMENT

HINT:
- The installation procedures are the removal procedures in reverse order. However, only installation procedures requiring additional information are included.
- A bolt without a torque specification is shown in the standard bolt chart.

1. REMOVE REAR SEAT CUSHION ASSEMBLY
2. REMOVE REAR SEATBACK ASSEMBLY LH
3. REMOVE REAR SEATBACK ASSEMBLY RH
4. REMOVE ROOF HEADLINING ASSEMBLY
a. Remove the seatback hinge LH and RH.
b. Remove the front door scuff plate LH and RH.
c. Remove the quarter trim panel front LH and RH.
d. Remove the center pillar garnish LH and RH.
e. Remove the roof side garnish inner LH and RH.
f. Remove the quarter trim panel upper LH and RH.
g. Partially remove the roof headlining.

HINT: It is not necessary to completely remove the roof headlining. Slightly lower the rear section of the roof headlining so that the back window glass can be removed later in step 7.

5. REMOVE PACKAGE TRAY TRIM PANEL ASSEMBLY




6. REMOVE BACK WINDOW MOULDING OUTSIDE
a. Using a knife, cut off the moulding as shown in the illustration.

NOTE: Be careful not to damage the vehicle body with the knife.

b. Remove the remaining moulding.

HINT: Make a partial cut in the moulding. Then, pull and remove it by hand.




7. REMOVE BACK WINDOW GLASS
a. Apply protective tape to the outer surface of the vehicle body to minimize scratches.
b. From the interior, insert piano wires between the vehicle body and back window glass as shown in the illustration.
c. Tie objects that can serve as handles (for example, wooden blocks) to all wire ends.

NOTE: When separating the back window glass from the vehicle, be careful not to damage the vehicle's paint or interior/exterior ornaments.




d. Place matchmarks over the back window glass and vehicle body on the locations indicated in the illustration.

HINT: Matchmarks do not need to be placed if the back window glass is not going to be reused.

e. Cut through the adhesive by pulling the piano wire around the back window glass.
f. Disengage the stoppers.
g. Using a suction cup, remove the back window glass.

NOTE: Leave as much adhesive on the vehicle body as possible when removing the back window glass.




8. CLEAN BACK WINDOW GLASS
a. Using a scraper, remove the damaged stoppers and adhesive sticking to the back window glass.
b. Clean the outer edges of the back window glass with white gasoline.

NOTE:
- Do not touch the back window glass surface after cleaning it.
- Even if using new back window glass, clean the back window glass with white gasoline.




9. CLEAN VEHICLE BODY
a. Clean and shape the contact surface of the vehicle body.
1. On the contact surface of the vehicle body, use a knife to cut away excess adhesive as shown in the illustration.

HINT: Leave as much adhesive on the vehicle body as possible.

NOTE: Be careful not to damage the vehicle body.

2. Clean the contact surface of the vehicle body with cleaner.

HINT: Even if all the adhesive has been removed, clean the vehicle body.




10. INSTALL BACK WINDOW GLASS STOPPER NO. 2
a. Apply Primer G to the installation part of the stoppers.

NOTE:
- Allow the Primer G to dry for 3 minutes or more.
- Throw away any leftover Primer G.
- Do not apply too much Primer G.




b. Install 2 new stoppers onto the back window glass as shown in the illustration.




11. INSTALL BACK WINDOW GLASS STOPPER NO. 1
a. Install 2 new stoppers to the vehicle body as shown in the illustration.




12. INSTALL BACK WINDOW GLASS
a. Position the back window glass.
1. Using a suction cup, place the back window glass in the correct position.
2. Check that the entire contact surface of the back window glass rim is perfectly even.
3. Place matchmarks over the back window glass and vehicle body on the locations indicated in the illustration.

HINT:
- Placing matchmarks is only necessary if the back window glass being installed is new. If it is reused back window glass, matchmarks should already be present.
- When reusing the back window glass, check and correct the matchmark position.

NOTE: Check that the stoppers are attached to the vehicle body correctly.

4. Using a suction cup, remove the back window glass.




b. Using a brush, apply Primer M to the exposed part of the vehicle body.

NOTE:
- Allow the Primer M to dry for 3 minutes or more.
- Do not apply Primer M to the adhesive.
- Throw away any leftover Primer M.
- Do not apply too much Primer M.




c. Using a brush or sponge, apply Primer G to the contact surface of the back window glass.

HINT: If Primer G is applied to an area other than that which is specified, wipe off the primer with white gasoline before it dries.

NOTE:
- Allow the Primer G to dry for 3 minutes or more.
- Throw away any leftover Primer G.
- Do not apply too much Primer G.







d. Apply adhesive to the back window glass.
Adhesive: Part No.08850-00801 or equivalent

1. Cut off the tip of the cartridge nozzle.

HINT: After cutting off the tip, use all adhesive within the time written in the table below.

2. Load the sealer gun with the cartridge.




3. Apply adhesive to the back window glass as shown in the illustration.




e. Install the back window glass to the vehicle body.
1. Using a suction cup, position the back window glass so that the matchmarks are aligned. Press it in gently along the rim.
2. Lightly press the front surface of the back window glass to ensure that the back window glass is securely fit to the vehicle body.

NOTE:
- Check that the stoppers are attached to the vehicle body correctly.
- Check that the vehicle body and back window glass have a small gap between them.

3. Hold the back window glass in place securely with protective tape or equivalent until the adhesive hardens.

13. INSTALL BACK WINDOW MOULDING OUTSIDE
a. Using a brush or sponge, apply Primer G to the contact surface of the back window glass.

NOTE:
- Allow the Primer G to dry for 3 minutes or more.
- Throw away any leftover Primer G.
- Do not apply too much Primer G.




b. Install new back window moulding outside before the adhesive dries.

NOTE: Do not drive the vehicle for the amount of time written in the table.

14. CHECK FOR LEAKS AND REPAIR
a. Conduct a leak test after the adhesive has completely hardened.
b. Seal any leaks with auto glass sealer.
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