Disconnect the rear window defogger terminals (A).
2.
Remove the side seals (A).
Cutting positions
3.
With a helper 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 tailgate, and carefully cut through the adhesive (C) around the entire rear window.
4.
Carefully remove the rear window.
5.
Scrape the original adhesive smooth to 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 with a putty knife.
NOTE:
Do not scrape down to the painted surface of the tailgate; damaged paint will interfere with proper bonding.
Remove the fasteners from the tailgate.
6.
If the original rear window (A) will be reinstalled, make alignment marks (B) across the rear window and the tailgate with a grease pencil.
7.
Apply protective tape along the inside and outside edges of the tailgate. 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.
1.
Rear Window - Install
1.
Clean the body bonding surface with a shop towel dampened with isopropyl alcohol. After cleaning, do not allow oil, grease, and water to contact on the clean surface.
2.
If you are reinstalling the original rear window, scrape off the original adhesive, the fasteners, seals, and the rubber dams from the rear window with a putty knife. Clean the bonding surface 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.
3.
Attach the new fasteners (A, B) with the adhesive tape to the inside face of the rear window (C) as shown.
NOTE:
Before installing the fasteners, apply glass primer to the area where the adhesive tape will be applied.
Be careful not to touch the rear window where the adhesive will be applied.
Make sure the fasteners line up with the alignment marks (D).
4.
Attach the new fasteners (A, B) with the adhesive tape to the rear window opening flange of the tailgate as shown.
5.
Install the side seals (A) with adhesive tape to the inside face of the rear window (B) as shown. Before installing the side seals, apply primer to the area where the adhesive tape will be applied to the inside face of the rear window.
NOTE:
Install the side seals to the rear window, using the alignment marks (C) on the rear window as the guides.
After installing the new side seals, cut the both ends of side seals flush with the edges of the glass as shown.
6.
Cut the seals to each length, then install the new upper seal (A) and the new lower seal (B). Before installing the seals, apply primer to the area where the adhesive tape will be applied to the inside face of the rear window.
Seal length:
Upper seal:
803 mm (31.61 in)
Lower seal:
925 mm (36.42 in)
NOTE:
Be careful not to touch the rear window where the adhesive will be applied.
Install the seals to the rear window, using the alignment marks (C) on the rear window as the guides.
7.
Apply a light coat of glass primer as shown, then lightly wipe it off with gauze or cheesecloth.
Apply the glass primer to the rear window (A) using the printed dots (B) on the rear window as a guide.
Do not apply body primer to the rear window, and do not 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 primed surfaces.
8.
Apply a light coat of the body primer to any exposed paint or metal on the windshield 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.
Set the rear window in the opening, and center it. Make alignment marks (A) across the rear window and the body with a grease pencil at the four points shown:
Make sure the pins (B) of the fasteners (C) contact with the edge of the body holes.
Be careful not to touch the rear window where the adhesive will be applied.
10.
Remove the rear window.
11.
Cut a ‘‘V’’ in the end of the nozzle (A) on the adhesive cartridge as shown.
12.
Put the cartridge in a caulking gun, and run a continuous bead of adhesive (A) around the edge of the rear window (B) as shown.
Apply the adhesive to both side areas of the rear window using the printed dots (C) on the rear window as a guide.
Apply the adhesive within 30 minutes after applying the glass primer.
Make a slightly thicker bead at each corner.
13.
Hold the rear window with suction cups over the opening, align it with the alignment marks you made, 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.
NOTE: Do not open or close any of the doors for about an hour until the adhesive is dry.
14.
Remove the excess adhesive with a putty knife or a shop towel dampened with isopropyl alcohol.
15.
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.
16.
Advise the customer not to do the following things for 2 to 3 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).
