Repair Procedure

How to use this service information .

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: Torque, N.m (lbf.ft)

: Replace

: Warning/Caution

: Inspection/Adjustment

*: Learning

: SPL Tool

: Required Removal

*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

1. Disconnect the terminals (a). (Figure 1)

Figure 1

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2. Remove the rear window upper molding from the rear window. If necessary, cut off the molding with a utility knife. (Figure 2)

Figure 2

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3. If the original rear window (b) will be reinstalled, make alignment marks (c) across the rear window and the tailgate with a grease pencil. (Figure 3)

Figure 3

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4. Apply protective tape along the inside and outside edges of the body. Make a hole with an awl or similar tool, through the adhesive (d) 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 4 and 5)

Figure 4 (Cutting positions)

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Figure 5 (Cutting positions)

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5. 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, and carefully cut through the adhesive around the entire rear window. (Figure 4 and 5)6. Carefully remove the rear window.

7. 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 upper 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 upper clips (f) and fastener A (g) with the adhesive tape on the inside face of the rear window as shown. (Figure 6)

NOTE:

Before installing the upper clips and fastener A, 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 upper clips and fastener A line up with the alignment marks (h). (Figure 6)

Specifications (Figure 5)

Standard Value
i	21 mm (0.83 in)

Figure 6

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4. Install the new rear window upper molding (k) with adhesive tape on the rear window (m) as shown. (Figure 7)

NOTE: Before installing the rear window upper molding apply glass primer (n) to the area where the adhesive tape will be applied.
Be careful not to touch the rear window where the adhesive will be applied.

Specifications (Figure 7)

Standard Value
o	6.5 mm (0.256 in)
p	0 +0 -3.0 mm (0 +0 -0.118 in)

Figure 7

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5. Install new rubber dams with the adhesive tape on the inside face of the rear window as shown. (Figure 8)

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 (q). (Figure 8)

Rubber Dam Cutting Length (Figure 8)

Position	Standard Value
r	619.3 mm (24.382 in)
s	818.8 mm (32.236 in)

Specifications (Figure 8)

Standard Value
t	0 mm (0 in)
u	3.5 mm (0.138 in)
v	30 mm (1.18 in)

Figure 8

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6. Install the fastener B (w) with the adhesive tape to the rear window opening flange of the body. (Figure 9)

Figure 9

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7. Set the rear window (x) in the opening, and center it. Make alignment marks (y) across the rear window and the body with a grease pencil at the four points shown. (Figure 10)

Be careful not to touch the rear window where the adhesive will be applied.

Figure 10

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8. Remove the rear window

9. Apply a light coat of primer (z) as shown, then lightly wipe it off with gauze or cheesecloth. (Figure 11)

NOTE: Apply the primer to both side areas of the rear window (aa) using the printed dots (ab) on the rear window as a guide. (Figure 11)
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 11)

Standard Value
ac	5.5 mm (0.217 in)
ad	11 mm (0.43 in)
ae	8.5 mm (0.335 in)
af	9 mm (0.35 in)
ag	3.5 mm (0.138 in)

Figure 11

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10. 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 the glass primer applicatiors.
Never touch the primed surfaces with your hands.

11. Cut a "V" on the end of the nozzle (ah) on the adhesive cartridge as shown. (Figure 12)

Specifications (Figure 12)

Standard Value
ai	12 mm (0.47 in)
ak	7 mm (0.28 in)

Figure 12

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12. Put the cartridge in a caulking gun, and run a continuous bead of adhesive (am) around the edge of the rear window (an) as shown. (Figure 13)

Apply the adhesive to both side areas of the rear window using the printed dots (ao) on the rear window as a guide. (Figure 13)
Apply the adhesive within 30 minutes after applying the glass primer.
Make a slightly thicker bead at each corner.

Specifications (Figure 13)

Standard Value
ap	12 mm (0.47 in)
aq	7 mm (0.28 in)
ar	2 mm (0.08 in)
as	5.5 mm (0.217 in)
at	10.5 mm (0.413 in)
au	11 mm (0.43 in)

Figure 13

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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 client not to do the following for 2 to 3 days:

Close the doors hard with all the windows rolled up.
Twist the body excessively (going in and out of driveways at an angle or driving over rough, uneven roads).

17. Connect the connectors (av). (Figure 14)

Figure 14

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