Ford Workshop Service and Repair Manuals > Mondeo 1997 (08.1996-09.2000) > Mechanical Repairs | 5 Body and Paint | 501 Body and Paint | 501-11 Glass, Frames and Mechanisms | Description and Operation | Diagnosis and Testing | Removal and Installation

Glass, Frames and Mechanisms - Rear Window Glass

Mondeo 1997 (08/1996-09/2000)

Removal and Installation

Removal

NOTE:Should the ambient temperature fall below 10°C, heat the cartridges for approximately 15 minutes by placing them on a warm radiator, or by using a hot air gun set at approximately 25°C.

Heat the polyurethane (PU) adhesive if necessary.

NOTE:Position the electrical connectors clear of the cutter blade path.

Disconnect the heated rear window electrical connectors on each side.
1. Remove the heated rear window electrical connector covers on each side.
1. Disconnect the heated rear window electrical connectors on each side.

Remove the heated rear window wiper motor (if equipped). For additional information, refer to Section 501-16 Wipers and Washers.

WARNING:Wear gloves and eye protection when working with the glass cutting tool as the cutting operation may produce splinters. When using the Fein cutter wear ear protection. Failure to follow these instructions may result in personal injury.

NOTE:If the original heated rear window is to be re-installed, make sure the cutter blade is kept low when cutting in the area of the heated rear window electrical connectors.

Cut around the window using the Fein oscillating cutter fitted with Fein cutter blade number 6 39 03 076 01 6.

With the aid of another technician, use suction cups to remove the heated rear window glass.

Installation

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.

CAUTION:Avoid touching the trimmed surface as this will inhibit the bonding of the new adhesive.

Remove the excess PU adhesive from the opening using the Fein oscillating cutter fitted with Fein cutter blade number 6 39 03 113 02 2.
- Carefully trim the remaining PU adhesive from the window opening to leave approximately 1 mm of trimmed PU adhesive adhered to the opening flange.

If the original heated rear window is to be re-installed, remove the excess PU adhesive from the glass as described in the previous step.

Check the pinch weld sealing area 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 to the rear window opening flange and glass bond line to remove all traces of moisture.

Prepare the glass, rear window opening flange and trimmed PU adhesive in accordance with the instructions supplied with the 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 should be overlapped by 20 mm.

Apply the PU adhesive in a continuous bead of between 8 and 10 mm height to the rear window opening flange along the bond line.

NOTE:Firmly and evenly press in position.

With the aid of another technician, use suction cups to install the heated rear window glass.

Should the ambient temperature fall below 10°C, use a hot air gun at a distance of approximately 50 mm from the surface and apply warm air (25°C) continuously for 15 minutes (inside or outside the vehicle).

Install the heated rear window wiper motor (if equipped). For additional information, refer to Section 501-16 Wipers and Washers.

Connect the heated rear window electrical connectors on each side.
1. Connect the heated rear window electrical connectors on each side.
1. Install the heated rear window electrical connector covers on each side.

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