NOTE: Take care not to bend the headliner excessively, or you may crease or break it.
3.
If the original rear window will be reinstalled, make the alignment marks across the rear window and the body with a grease pencil.
4.
Apply the protective tape along the inside and outside edges of the body. Make a hole with an awl through the adhesive from inside the vehicle at a corner of the rear window. Push a piece of piano wire through the hole, and wrap each end around a piece of wood.
5.
Open the trunk lid.
6.
Remove the rubber dam (A) from the lower edge of the rear window (B). If necessary, cut the rubber dam with a utility knife.
Cutting Positions
7.
With an assistant on the outside, pull the piano wire (A) back and forth in a sawing motion. Hold the piano wire as close to the rear window (B) as possible to prevent damage to the body, and carefully cut through the adhesive (C) around the entire rear window.
8.
Carefully remove the rear window.
9.
Scrape smooth the original adhesive with a knife, until there is a thickness of about 1 mm (0.04 in) - 2 mm (0.08 in) on the bonding surface around the entire rear window opening flange.
NOTE:
Do not scrape down to the painted surface of the body; damaged paint will interfere with proper bonding.
Remove the clips and the fasteners from the body.
10.
Clean the body bonding surface with a shop towel dampened with isopropyl alcohol. After cleaning, keep oil, grease, and water from getting on the surface.
11.
If you are reinstalling the original rear window, scrape off the original adhesive, the clips, the fasteners, and the rubber dams from the rear window with a putty knife. Clean the bonding surfaces on the inside face and the edge of the rear window with isopropyl alcohol. Make sure the bonding surface is kept free of water, oil, and grease.
If the original rear window will be reinstalled, make the alignment marks across the rear window and the body with a grease pencil.
3.
Apply the protective tape along the inside and outside edges of the body. Make a hole with an awl through the adhesive from inside the vehicle at a corner of the rear window. Push a piece of piano wire through the hole, and wrap each end around a piece of wood.
4.
Open the tailgate.
5.
With an assistant on the outside, pull the piano wire (A) back and forth in a sawing motion. Hold the piano wire as close to the rear window (B) as possible to prevent damage to the body, and carefully cut through the adhesive (C) around the entire rear window.
6.
Carefully remove the rear window.
7.
Scrape smooth the original adhesive with a knife, until there is a thickness of about 1 mm (0.04 in) - 2 mm (0.08 in) on the bonding surface around the entire rear window opening flange.
NOTE:
Do not scrape down to the painted surface of the body; damaged paint will interfere with proper bonding.
Remove the clips and the fasteners from the body.
8.
Clean the body bonding surface with a shop towel dampened with isopropyl alcohol. After cleaning, keep oil, grease, and water from getting on the surface.
9.
If you are reinstalling the original rear window, scrape off the original adhesive, the clips, the fasteners, and the rubber dams from the rear window with a putty knife. Clean the bonding surfaces on the inside face and the edge of the rear window with isopropyl alcohol. Make sure the bonding surface is kept free of water, oil, and grease.
4-door
1.
Rear Window - Install
1.
Install the clips (A) and the fasteners (B) with the adhesive tape to the inside face of the rear window (C) as shown.
NOTE:
Be careful not to touch the rear window where the adhesive will be applied.
Before installing the clips, apply the glass primer to the area where the adhesive tape will be applied.
Make sure the index tabs (D) on the clips face the right side.
Make sure the clips and the fasteners line up with the alignment marks (E).
2.
Install the rubber dams (A, B, C) with the adhesive tape to the inside face of the rear window (D) as shown.
NOTE:
Be careful not to touch the rear window where the adhesive will be applied.
Make sure the rubber dams line up with the alignment marks (E).
Rubber dams
Length
(A)
1,075 mm (42.32 in)
(B)
18 mm (0.71 in)
(C)
749 mm (29.49 in)
3.
Install the rubber dam (A) with the adhesive tape to the inside face of the rear window (B) as shown.
NOTE:
Be careful not to touch the rear window where the adhesive will be applied.
Make sure the rubber dam line up with the alignment marks (C).
4.
Install the fasteners (A) with the adhesive tape to the rear window opening flange of the body as shown.
5.
If you are installing the new rear window (A), set the rear window in the opening, and center it. Make the alignment marks (B) across the rear window and the body with a grease pencil at the four points shown.
NOTE:
Be careful not to touch the rear window where the adhesive will be applied.
Make sure the clips (C) contact with the edge of the body holes.
6.
Remove the rear window.
7.
Apply a light coat of primer to the rear window (A) along the rubber dams (B, C) as shown, then lightly wipe it off with gauze or cheesecloth.
NOTE:
Apply the primer to the corner areas (D) of the rear window using the printed dots (E) on the rear window as a guide.
Do not apply the body primer to the rear window, and be careful not to mix up the body and glass primer applicators.
Never touch the primed surfaces with your hands. If you do, the adhesive may not bond to the rear window properly, causing a leak after the rear window is installed.
Keep water, dust, and abrasive materials away from the primed surfaces.
8.
Apply a light coat of the body primer to any exposed paint or metal on the rear window mounting flange. Let the body primer dry for at least 10 minutes.
NOTE:
Do not apply the glass primer to the body.
Do not apply the body primer to any remaining original adhesive on the flange.
Be careful not to mix up the body and glass primer applicators.
Never touch the primed surfaces with your hands.
9.
Cut a ‘‘V’’ at the end of the adhesive cartridge nozzle (A) as shown.
10.
Put the cartridge in a caulking gun, and run a continuous bead of the adhesive (A) to the rear window (B) along the rubber dams (C, D) as shown.
NOTE:
Apply the adhesive within 30 minutes after applying the glass primer.
Apply the adhesive to the corner areas (E) of the rear window using the printed dots (F) on the rear window as a guide.
Make a slightly thicker bead at each corner.
11.
Hold the rear window with the suction cups over the opening, align it with the alignment marks you made in step 5, and set it down on the adhesive. Lightly push on the rear window until its edges are fully seated on the adhesive all the way around. Carefully remove the suction cups.
NOTE: Do not open or close any of the doors for about an hour until the adhesive is dry.
12.
Remove the excess adhesive with a putty knife or a shop towel dampened with isopropyl alcohol.
13.
Wait at least an hour for the adhesive to dry, then spray water over the rear window and check for leaks. Mark the leaking areas, let the rear window dry, then seal with sealant. Let the vehicle stand for at least 4 hours after rear window installation. If the vehicle has to be used within the first 4 hours, it must be driven slowly.
14.
Advise the customer not to do the following things for 2 to 3 days:
Do not slam the doors with all the windows rolled up.
Do not twist the body excessively (such as when going in and out of driveways at an angle or driving over rough, uneven roads).
Install the fasteners (A) with the adhesive tape to the inside face of the rear window (B) as shown.
NOTE:
Be careful not to touch the rear window where the adhesive will be applied.
Before installing the fasteners the glass primer to the area where the adhesive tape will be applied.
Make sure the fasteners line up with the alignment marks (C).
2.
Install the rubber dams (A) with the adhesive tape to the inside face of the rear window (B) as shown.
NOTE:
Be careful not to touch the rear window where the adhesive will be applied.
Make sure the rubber dams line up with the alignment marks (C).
Rubber dams (A):
Length 40 mm (1.57 in)
3.
Install the seal (D) line up with the alignment marks (E).
4.
Install the rubber dams (A, B, C) with the adhesive tape to the inside face of the rear window (D) as shown.
NOTE:
Be careful not to touch the rear window where the adhesive will be applied.
Make sure the rubber dams line up with the alignment marks (E).
Rubber dams
Length
(A)
1,000 mm (39.37 in)
(B)
605 mm (23.82 in)
(C)
975 mm (38.39 in)
5.
Install the fasteners (A) with the adhesive tape to the rear window opening flange of the tailgate as shown.
6.
If you are installing the new rear window (A), set the rear window in the opening, and center it. Make the alignment marks (B) across the rear window and the tailgate with a grease pencil at the four points shown.
NOTE: Be careful not to touch the rear window where the adhesive will be applied.
7.
Remove the rear window.
8.
Apply a light coat of primer to the rear window (A) along the rubber dams (B) as shown, then lightly wipe it off with gauze or cheesecloth.
NOTE:
Apply the primer to the corner areas (C) of the rear window using the printed dots (D) on the rear window as a guide.
Do not apply the body primer to the rear window, and be careful not to mix up the body and glass primer applicators.
Never touch the primed surfaces with your hands. If you do, the adhesive may not bond to the rear window properly, causing a leak after the rear window is installed.
Keep water, dust, and abrasive materials away from the primed surfaces.
9.
Apply a light coat of the body primer to any exposed paint or metal on the rear window mounting flange. Let the body primer dry for at least 10 minutes.
NOTE:
Do not apply the glass primer to the body.
Do not apply the body primer to any remaining original adhesive on the flange.
Be careful not to mix up the body and glass primer applicators.
Never touch the primed surfaces with your hands.
10.
Cut a ‘‘V’’ at the end of the adhesive cartridge nozzle (A) as shown.
11.
Put the cartridge in a caulking gun, and run a continuous bead of the adhesive (A) to the rear window (B) along the rubber dams (C) as shown.
NOTE:
Apply the adhesive within 30 minutes after applying the glass primer.
Apply the adhesive to the corner areas (D) of the rear window using the printed dots (E) on the rear window as a guide.
Make a slightly thicker bead at each corner.
12.
Hold the rear window with the suction cups over the opening, align it with the alignment marks you made in step 6, and set it down on the adhesive. Lightly push on the rear window until its edges are fully seated on the adhesive all the way around. Carefully remove the suction cups.
NOTE: Do not open or close any of the doors for about an hour until the adhesive is dry.
13.
Remove the excess adhesive with a putty knife or a shop towel dampened with isopropyl alcohol.
14.
Wait at least an hour for the adhesive to dry, then spray water over the rear window and check for leaks. Mark the leaking areas, let the rear window dry, then seal with sealant. Let the vehicle stand for at least 4 hours after rear window installation. If the vehicle has to be used within the first 4 hours, it must be driven slowly.
15.
Advise the customer not to do the following things for 2 to 3 days:
Do not slam the doors with all the windows rolled up.
Do not twist the body excessively (such as when going in and out of driveways at an angle or driving over rough, uneven roads).
