| Removal and Installation Hot air gun Direct glazing cutter for bonded glass Direct glazing adhesive kit Direct glazing adhesive oven Glazing suction cups Removal | | -
Remove the polyurethane (PU) adhesive cap and heat the PU adhesive for a minimum of 30 minutes. | | | -
Remove the C-pillar trim panel.
For additional information, refer to: C-Pillar Trim Panel - Wagon (501-05 Interior Trim and Ornamentation, Removal and Installation).
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WARNING:Wear gloves and eye protection when working with the direct glazing cutter for bonded glass as the cutting operation may produce splinters. When using the direct glazing cutter for bonded glass wear ear protectors. Failure to follow these instructions may result in personal injury. CAUTION:Place a suitable piece of flexible plastic card between the direct glazing cutter for bonded glass cutting blade and vehicle body to avoid damage to the vehicle body when cutting from outside the vehicle. CAUTION:Make sure that the direct glazing cutter for bonded glass cutting blades are changed where the cutting depth changes to avoid damage to the vehicle body and trim panels when cutting from inside the vehicle. NOTE:Some resistance may be encountered when cutting through the rear quarter window glass locating pegs in the corners of the glass. - From outside the vehicle, cut the PU adhesive.
- From inside the vehicle, cut the PU adhesive to a maximum depth of 20 mm.
| Installation | | -
Carefully remove the remaining part of the rear quarter window glass locating pegs from the rear quarter window glass flange. | | | -
CAUTION:Do not touch the adhesive surface as re-bonding will be impaired. Carefully trim the remaining PU adhesive from the rear quarter window glass flange to leave approximately 1 mm of trimmed PU adhesive adhered to the rear quarter window glass flange. | | | -
Check the rear quarter 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 rear quarter window glass flange and rear quarter window glass bond line to remove all traces of moisture. | | | -
Prepare the rear quarter window glass, rear quarter window glass flange and trimmed PU adhesive in accordance with the instructions supplied with the direct glazing adhesive kit. | | | -
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 rear quarter window glass flange along the bond line. | | | -
- 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 opened and closed. Using suitable tape, secure the rear quarter window glass in the correct position until the PU adhesive has cured. | | | -
If the ambient temperature falls below 10°C, using a hot air gun, apply warm air (25°C) continuously for 15 minutes along the bond line (inside or outside the vehicle). | | | -
Install the C-pillar trim panel.
For additional information, refer to: C-Pillar Trim Panel - Wagon (501-05 Interior Trim and Ornamentation, Removal and Installation).
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