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Quarter Glass Replacement

NOTE:
  • Put on gloves to protect your hands.
  • Wear eye protection while cutting the glass adhesive with a piano wire.
  • Use seat covers to avoid damaging any surfaces.
  1. Remove the quarter pillar trim (see QUARTER PILLAR TRIM ).
  2. Remove the rear lower rubber dam (A) from the front edge of the quarter glass (B). If necessary, cut the rubber dam with a utility knife.
    Fig 1: Identifying Rear Lower Rubber Dam
    G05456191Courtesy of AMERICAN HONDA MOTOR CO., INC.
  3. Apply protective tape to along the inside and outside edges of the body. Using an awl, make a hole through the adhesive from inside the vehicle. Push a piece of piano wire through the hole, and wrap each end around a piece of wood.
  4. 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 quarter glass (B) as possible to prevent damage to the body, and carefully cut through the adhesive (C) around the entire quarter glass.
    Fig 2: Cutting Adhesive Around Entire Quarter Glass
    G05456192Courtesy of AMERICAN HONDA MOTOR CO., INC.

    Cutting positions 

    Fig 3: Identifying Quarter Glass Cutting Positions
    G05456193Courtesy of AMERICAN HONDA MOTOR CO., INC.
  5. Carefully remove the quarter glass.
  6. With a putty knife, scrape the old adhesive smooth to a thickness of about 2 mm (0.08 in.) on the bonding surface around the entire quarter glass opening flange:
    • Do not scrape down to the painted surface of the body; damaged paint will interfere with proper bonding.
    • Remove the clips and fastener from the body.
  7. Clean the body bonding surface with a sponge dampened in alcohol. After cleaning, keep oil, grease and water from getting on the surface.
  8. If the old quarter glass is to be reinstalled, use a putty knife to scrape off all of the old adhesive, fastener and the rubber dam from the quarter glass. Clean the inside face and the edge of the quarter glass with alcohol where new adhesive is to be applied. Make sure the bonding surface is kept free of water, oil and grease.
  9. Set the quarter glass (A) in the opening, and center it. From inside the vehicle, make alignment mark (B) to the quarter glass where the rear clip will be installed with a grease pencil. Be careful not to touch the glass where adhesive will be applied.
    Fig 4: Identifying Alignment Mark On Quarter Glass
    G05456194Courtesy of AMERICAN HONDA MOTOR CO., INC.
  10. Remove the quarter glass.
  11. Attach the rear upper rubber dam (A), rubber dam (B), rear lower rubber dam (C), upper clip (D), lower clip (E), and rear clip (F) with adhesive tape to the inside face of the quarter glass (G) as shown:
    • First glue the front upper rubber dam to the bottom of the quarter glass trim, then glue the other rubber dams around the edge of the quarter glass. Be sure top of the front lower rubber dam contacts bottom of the front upper rubber dam. If necessary, cut the rubber dam.
    • Align the center of the rear clip with the alignment mark (H) you made in step  9.
    • Be careful not to touch the quarter glass where adhesive will be applied.

    Rear upper rubber dam adhesive tape: 

    • Thickness 0.2 mm (0.008 in.) 
    • Width 4 mm (0.16 in.) 

    Rear lower rubber dam adhesive tape: 

    • Thickness 0.16 mm (0.006 in.) 
    • Width 3 mm (0.12 in.) 

    Rubber dam adhesive tape: 

    • Thickness 0.16 mm (0.006 in.) 
    • Width 3.5 mm (0.14 in.) 

    Upper clip adhesive tape: 

    • Thickness 1.3 mm (0.05 in.) 
    • Width 9 mm (0.35 in.) 

    Lower clip adhesive tape: 

    • Thickness 1.3 mm (0.05 in.) 
    • Width 11 mm (0.22 in.) 

    Rear clip adhesive tape: 

    • Thickness 0.4 mm (0.02 in.) 
    • Width 7.5 mm (0.30 in.) 
    Fig 5: Identifying Adhesive Tape To Inside Face Of Quarter Glass
    G05456195Courtesy of AMERICAN HONDA MOTOR CO., INC.
  12. With a sponge, apply a light coat of glass primer along the edge of the quarter glass (A) and rubber dams (B) as shown, then lightly wipe it off with gauze or cheesecloth:
    • With the printed dots (C) on the quarter glass as a guide, apply the glass primer to the upper and lower corner portions of the quarter glass.
    • Do not apply body primer to the quarter 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 quarter glass properly, causing a leak after the quarter glass is installed.
    • Keep water, dust, and abrasive materials away from the primed surface.
      • Fig 6: Applying Light Coat Of Glass Primer Along Edge Of Quarter Glass And Rubber Dams
      G05456196Courtesy of AMERICAN HONDA MOTOR CO., INC.
  13. With a sponge, apply a light coat of body primer to the original adhesive remaining around the quarter glass opening flange. Let the body primer dry for at least 10 minutes:
    • Do not apply body primer to any remaining original adhesive on the flange.
    • Be careful not to mix up the body and glass primer sponges.
    • Never touch the primed surfaces with your hands.
      • Fig 7: Identifying Glass Primer Area On Quarter Glass
      G05456197Courtesy of AMERICAN HONDA MOTOR CO., INC.
  14. Cut a "V" in the end of the nozzle (A) on the adhesive cartridge as shown.
    Fig 8: Cutting "V" At End Of Adhesive Cartridge Nozzle
    G05456198Courtesy of AMERICAN HONDA MOTOR CO., INC.
  15. Pack adhesive into the cartridge without air pockets to ensure continuous delivery. Put the cartridge in a caulking gun, and run a bead of adhesive (A) around the edge of the quarter glass (B) and along the rubber dams (C) as shown. With the printed dots on the quarter glass as a guide, apply the adhesive to the upper and lower corner portions of the quarter glass. Apply the adhesive within 30 minutes after applying the glass primer. Make a slightly thicker bead at each corner.
    Fig 9: Identifying Bead Of Adhesive Around Edge Of Quarter Glass And Rubber Dams
    G05456199Courtesy of AMERICAN HONDA MOTOR CO., INC.
  16. Use suction cups (A) to hold the quarter glass (B) over the opening, align it with the clips (C) and set it down on the adhesive. Lightly push on the quarter glass 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.
    Fig 10: Holding Quarter Glass Using Suction Cups
    G05456200Courtesy of AMERICAN HONDA MOTOR CO., INC.
  17. Scrape or wipe the excess adhesive off with a putty knife or towel. To remove adhesive from a painted surface or the quarter glass, use a soft shop towel dampened with alcohol.
  18. After the adhesive has dried, spray water over the quarter glass and check for leaks. Mark the leaking areas, let the quarter glass dry, then seal with sealant. Let the vehicle stand for at least 4 hours after quarter glass installation. If the vehicle has to be used within the first 4 hours, it must be driven slowly.
  19. Reinstall ail remaining removed parts.
    NOTE: 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).
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