Carefully cut through the rubber dam (B) with a utility knife.
NOTE: Apply protective tape along the inside and outside edges of the body.
Cutting positions
3.
Make a hole with an awl through the adhesive from inside the vehicle. Push a piece of piano wire (A) through the hole, and wrap each end around a piece of wood.
4.
With a helper on the outside, pull the piano wire back and forth in a sawing motion. Hold the piano wire as close to the front corner glass (B) as possible to prevent damage to the body, and carefully cut through the adhesive (C) around the entire front corner glass.
5.
Carefully cut through the adhesive (A) at the front corner area of the front corner glass (B) with a utility knife.
6.
If the original front corner glass (A) will be reinstalled, make alignment marks (B) across the front corner glass and the body with a grease pencil.
7.
Carefully remove the front corner glass (A) with suction cups (B).
8.
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 front corner glass opening flange with a putty knife.
NOTE:
Do not scrape down to the painted surface of the body; damaged paint will interfere with proper bonding.
Remove the clips from the body.
1.
Quarter Glass - Install
1.
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.
2.
If you are reinstalling the original front corner glass, scrape off the original adhesive, with a putty knife and the damaged clips from the front corner glass. Clean the bonding surfaces on the inside face and the edge of the front corner glass with isopropyl alcohol. Make sure the bonding surface is kept free of water, oil, and grease.
3.
Install the new clips (A) with adhesive tape to the inside face of the front corner glass (B) as shown.
NOTE:
Before installing the clips, seal and molding, apply glass primer to the area where the adhesive tape will be applied.
Make sure the clip line up with the alignment marks (E).
After installing the seal and the molding, cut ends of the seal and the molding as shown.
4.
Apply a light coat of glass primer along the edge of the new rubber dam (A) as shown, then lightly wipe it off with gauze or cheesecloth.
NOTE:
Install the front corner glass (B) with the printed dots (C) on the front corner glass as a guide.
Do not apply body primer to the front corner 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 front corner glass properly, causing a leak after the front corner glass is installed.
Keep water, dust, and abrasive materials away from primed surfaces.
5.
Cut the rubber dam to the length, then install the new rubber dam (A).
Rubber dam length:
Rubber dam:
119 mm (4.69 in)
6.
Apply a light coat of glass primer along the edge of the rubber dam (A) as shown, then lightly wipe it off with gauze or cheesecloth.
NOTE:
With the printed dots (B) on the front corner glass (C) as a guide, apply the glass primer to the front area of the front corner glass.
Do not apply body primer to the front corner 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 front corner glass properly, causing a leak after the front corner glass is installed.
Keep water, dust, and abrasive materials away from primed surfaces.
7.
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.
Cover on the dashboard before applying the body primer.
Be careful not to mix up the body and glass primer applicators.
Never touch the primed surfaces with your hands.
8.
Cut a ‘‘V’’ in the end of the nozzle (A) on the adhesive cartridge as shown.
9.
Put the cartridge in a caulking gun, and run a continuous bead of adhesive (A) around the rubber dam (B) as shown:
With the glass primer (C) you applied in step 6 on the front corner glass (D) as a guide when you apply the adhesive to the upper and lower corner areas of the front corner glass.
Apply the adhesive within 30 minutes after applying the glass primer. Make a slightly thicker bead at each corner.
10.
Hold the front corner glass (A) with suction cups (B) over the opening, align the clips (C) or the alignment marks (D), and set it down on the adhesive. Lightly push on the front corner glass 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.
11.
Remove the excess adhesive with a putty knife or a shop towel dampened with isopropyl alcohol.
12.
Wait at least an hour for the adhesive to dry, then spray water over the front corner glass and check for leaks. Mark the leaking areas, let the front corner glass dry, then seal with sealant. Let the vehicle stand for at least 4 hours after front corner glass installation. If the vehicle has to be used within the first 4 hours, it must be driven slowly.
13.
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).
