| Removal and Installation Hot air gun Direct glazing cutter for bonded glass Direct glazing adhesive kit Direct glazing adhesive oven Glazing suction cups Removal All vehicles | | -
Remove the polyurethane (PU) adhesive cap and heat the PU adhesive for a minimum of 30 minutes. | | | -
Remove the rear window wiper motor spindle grommet (if equipped). | Vehicles with heated rear window | | -
Detach the grommet from the liftgate. | | | -
Disconnect the heated liftgate window glass electrical connectors. | All vehicles | | -
WARNING:Wear gloves and eye protection when working with the glass cutting tool as the cutting operation may produce splinters. When using the cutter wear ear protectors. Failure to follow these instructions may result in personal injury. CAUTION:Make sure the cutting blades are changed where the cutting depth changes to avoid damage to the body and trim panels. NOTE:Some resistance may be encountered when cutting through the glass locating pegs in the corners of the glass. From inside the vehicle, using a suitable direct glazing cutter, cut the PU adhesive to the given maximum depths. - 30 mm.
- 35 mm.
- 28 mm.
- 25 mm.
- 24 mm.
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With the aid of another technician, use glazing suction cups to remove the liftgate window glass. | | | -
Remove and discard the liftgate window glass weatherstrip. | Installation All vehicles | | -
Carefully remove the remaining part of the locating pegs from the liftgate window glass flange. | | | -
CAUTION:Do not touch the adhesive surface as re-bonding will be impaired. Carefully trim the remaining PU adhesive from the liftgate glass flange to leave approximately 1 mm of trimmed PU adhesive adhered to the flange. | | | -
Check the liftgate window glass flange for damaged sheet metal, rust or foreign material which may have caused, or may cause, glass breakage. | | | -
CAUTION:To make sure that the PU adhesive cures, it is essential that all bonding surfaces are free of moisture. Using a hot air gun, apply warm air (25°C) to the liftgate window glass flange and glass bond line to remove all traces of moisture. | | | -
Prepare the glass, liftgate window glass flange and trimmed PU adhesive in accordance with the instructions supplied with the PU adhesive kit. | | | -
Install a new liftgate window glass weatherstrip. | | | -
NOTE:Discard the first 100 mm of PU adhesive as this may have a reduced working time. NOTE:To avoid water leaks, any breakage in the continuous bead must be overlapped by 20 mm. Apply the PU adhesive in a continuous bead of between 8 and 10 mm in height to the liftgate glass flange along the bond line. | | | -
With the aid of another technician, use glazing suction cups to install the liftgate window glass. - Press firmly and evenly into position.
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CAUTION:During the curing period of the PU adhesive, the door windows must be left open to avoid a build up of pressure when the doors are open and closed. Using suitable tape, secure the liftgate window glass in the correct position until the PU adhesive has cured. | | | -
If the ambient temperature falls below 10°C, use a hot air gun and apply warm air (25°C) continuously for 15 minutes (inside or outside the vehicle). | Vehicles with heated rear window | | -
Connect the heated liftgate window glass electrical connectors. | | | -
Attach the grommet to the liftgate. | All vehicles | | -
Install the rear window wiper motor spindle grommet (if equipped). | |
