Remove

Service Repair No. 76.81.20

Note: The following equipment is required:
Sharp knife.
Cutting wire and handles.
Suction lifters.
Windscreen repair kit.
Sealer applicator gun.

WARNING: Wear protective gloves when handling glass, solvents and primers.

Remove

1. Remove rear quarter upper trim.

2. Release trim stud at top of 'B' post and release door glass seal from 'B' post.
3. Remove cheater panel.
4. Remove upper and lower quarter glass finishers.

CAUTION: Care must be taken when releasing rear end of lower finisher from sealant.

5. Apply masking tape to body around quarter glass to protect paintwork.

6. Using a knife, cut through sealer and 2 body clips on forward edge of quarter glass.
7. Insert cutting wire through previously made knife cut and fit handles, as shown, with approximately 200mm of wire between handles.
8. With assistance, wedge the tube of handle A between the glass and body, ahead of the cutting position, and carefully cut the sealer using a continuous pull on handle B from the outside. Ensure that glass is retained as last of sealant is cut.

Note: If multi-strand cutting wire is used, a sawing action can be used to cut through heavy sealant deposits around corners.

CAUTION: Use of a sawing action may overheat and break single strand wire.

9. Remove rear quarter glass from body.

Refit

1. Carefully cut old sealer from body flange to obtain a smooth surface, approximately 2mm thick.

CAUTION: Do not cut down to painted surface.

2. Lay rear quarter glass panel on felt covered surface.
3. Apply cleaning solvent to sealing surface of glass and body flange.
   DO NOT TOUCH CLEANED OR PRIMED AREAS WITH FINGERS.
4. Shake primer tins for 30 seconds and apply body primer to sealing surface of body flange.
5. Apply glass primer to 12mm wide sealing surface on glass.

CAUTION: Use a new applicator sponge for each primer.

6. Remove lid from sealer cartridge, shake out crystals and fit pre-cut nozzle. Install cartridge in applicator gun.

7. Apply an even 12mm high x 8mm base bead of sealer around edge of quarter glass as shown.

Note: Make bead thicker at corners.

8. Fit spare nozzle to cartridge and apply 3mm bead of sealer to channels of upper and lower finishers.
9. Fit lower finisher to glass and fit upper finisher with end flush to forward edge of glass.
10. Attach suction lifters to glass and position glass to body.
11. Align clips to body and press evenly until clips are engaged and glass is fully seated.
12. Remove excess sealant with a knife and wipe from glass with solvent.
13. Remove masking tape.