Repair Procedure
| *: Learning | : ■SPL Tool |
| *1: Part(s) are shown for one side only as the procedure is the same for both sides. |
- A.-
Key Information
Do the following before starting your work.
Remove:
Sub-Procedure
Removal
Figure 1
1. Disconnect the terminals (a). (Figure 1)
2. If the original rear window will be reinstalled, make alignment marks (b) across the rear window and the tailgate with a grease pencil. (Figure 2)
Figure 2
3. Apply protective tape along the inside and outside edges of the body. Make a hole with an awl or similar tool, through the adhesive from inside the vehicle at a corner of the rear window. Push a piece of piano wire (e) through the hole, and wrap each end around a piece of wood. (Figure 3 and 4)
Figure 3 (Cutting positions)
Figure 4 (Cutting positions)
4. With an assistant on the outside, pull the piano wire back and forth in a sawing motion. Hold the piano wire as close to the rear window as possible to prevent damage to the tailgate. Carefully cut through the adhesive around the entire rear window. (Figure 3 and 4)
5. Carefully remove the rear window.
6. 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 body; damaged paint will interfere with proper bonding.
- Remove the clips and the rubber dams from the body.
Installation
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 the clean surface.
2. If you are reinstalling the original rear window, scrape off the original adhesive, the clip, fastener A, 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. Install the new clips (g) and fastener A (h) with the adhesive tape on the inside face of the rear window as shown (Figure 5).
NOTE:- Before installing the clips and fastener A apply glass primer to the area where the adhesive tape will be applied.
- Be careful not to touch the windshield where the adhesive will be applied.
- Make sure the clips and fastener A line up with the alignment marks (k) (Figure 5).
Specifications (Figure 5)
Standard Value m 24.6 mm (0.969 in) Figure 5
4. Install new rubber dams with the adhesive tape on the inside face of the rear window as shown (Figure 6).
NOTE:- Before installing the rubber dams, apply 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 rubber dams line up with the alignment marks (n) (Figure 6).
- After installing the new rubber dam, cut the ends of rubber dam flush with the edges of the glass as shown. (Figure 6)
Rubber Dam Cutting Length (Figure 6)
Position Standard Value o 1070 mm (42.13 in) p 695 mm (27.36 in) q 1146 mm (45.12 in) Specifications (Figure 6)
Standard Value r 6 mm (0.24 in) s 2 mm (0.08 in) t 20 mm (0.787 in) Standard Value u 5.3 mm (0.209 in) Figure 6
5. Install the fastener B (v) with the adhesive tape to the rear window opening flange of the body. (Figure 7)
Figure 7
6. Set the rear window (w) in the opening, and center it. Make alignment marks (x) across the rear window and the body with a grease pencil at the four points shown. (Figure 8)
- Be careful not to touch the rear window where the adhesive will be applied.
Figure 8
7. Remove the rear window.
8. Apply a light coat of primer (y) as shown, then lightly wipe it off with gauze or cheesecloth.
NOTE:- Apply the primer to both side areas of the rear window (z) using the printed dots (aa) on the rear window as a guide. (Figure 9)
- 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.
Specifications (Figure 9)
Standard Value ab 5.5 mm (0.217 in) ac 11 mm (0.43 in) ad 6 mm (0.24 in) ae 5.3 mm (0.209 in) af 2 mm (0.08 in) Figure 9
9. Carefully apply a light coat of body primer to any exposed paint or metal around the flange where new adhesive will be applied. Let the primer dry for at least 10 minutes.
NOTE:- Do not apply the glass primer to the body.
- Do not apply 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" in the end of the nozzle (ag) on the adhesive cartridge as shown. (Figure 10)
Specifications (Figure 10)
Standard Value ah 12 mm (0.47 in) ai 7 mm (0.28 in) Figure 10
11. Put the cartridge in a caulking gun, and run a continuous bead of adhesive (ak) around the edge of the rear window (am) as shown (Figure 11).
- Apply the adhesive to both side areas of the rear window using the printed dots (an) on the rear window as a guide (Figure 11).
- Apply the adhesive within 30 minutes after applying the glass primer.
- Make a slightly thicker bead at each corner.
Specifications (Figure 11)
Standard Value ao 12 mm (0.47 in) ap 7 mm (0.28 in) aq 2 mm (0.08 in) ar 11 mm (0.43 in) as 17.3 mm (0.681 in) at 6 mm (0.24 in) Figure 11
12. 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.
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 client 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).
16. Connect the terminals (au). (Figure 12)
Figure 12