Rear Quarter Light

Service repair no - 76.81.20


NOTE: The following equipment is required:
Masking tape.
Sharp knife.
Cutting wire and handles, or a reciprocating blade, powered cutting knife*.
Suction Lifters.
Windscreen repair kit.
Sealer applicator gun.

* A reciprocating blade cutting tool, such as 'FEIN Special Cutter' is recommended for this operation. A flat blade, with an effective length of at least 25 mm and a 'U' shaped blade of at least 30 mm is required.


NOTE: New rear quarter glass is supplied with exterior trim fitted.


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


Remove
1. Remove parcel tray support.
2. Remove both 'E' post trims. Service and Repair
3. Remove relevant 'B' post upper trim. Service and Repair
4. Remove relevant side interior lamp assembly. Service and Repair
5. Remove relevant grab handle.
6. Remove relevant exterior 'E' post finisher. Service and Repair
7. Remove 2 trim studs securing headlining to 'E' posts.







8. Release headlining from tailgate seal. Lower headlining as necessary during glass removal to provide access to sealant along top edge of glass.
9. Disconnect aerial amplifier plugs.







10. R.H. glass only: Disconnect alarm receiver plug.
11. Protect surrounding area of body using masking tape.

Removal Using Reciprocating Blade Tool
12. Lift flip seal to reveal trim fixings.







13. Remove 2 screws securing exterior trim to 'D' post.
14. Cut through P.U. adhesive from inside of glass along lower and side edges.







CAUTION: Manoeuvre knife blade around 3 parcel tray support clips. Ensure aerial amplifier and alarm receiver plugs do not become damaged.


15. Attach suction lifters to glass. With assistance, cut through sealant along top of edge glass.
16. Remove rear quarter glass.

Removal Using Cutting Wire Handles
17. Protect surrounding area of body using masking tape.
18. Lift flip seal to reveal trim fixings.
19. Remove 2 screws securing exterior trim to 'D' post.








20. Carefully cut through adhesive bead between glass and trim using a sharp knife.


NOTE: A reciprocating blade cutting tool, such as 'FEIN Special Cutter' will ease the removal of the trim. Use a cranked blade with an effective length of not more than 22 mm.


21. Remove and discard quarter light trim.


NOTE: Rear quarter lights are supplied with finisher fitted. Finisher is not available separately.


22. Using a sharp knife, cut through P.U. sealer at forward edge of quarter glass.
23. Insert cutting wire through knife cut and fit handles, as shown, with approximately 200 mm of wire between handles.







24. With assistance, wedge tube of handles 'A' between glass and body, ahead of the cutting position, and carefully cut the sealer using a continuous pull on handle 'B' from the outside. Cut side and top edges first. Attach suction lifters as last sealant is cut.


NOTE: When cutting along lower edge, manoeuvre wire between glass edge and parcel tray support clips to reduce strain on wire.


CAUTION: Ensure aerial amplifier and alarm receiver plugs do not become damaged.


25. Remove rear quarter glass.

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


CAUTION: Do not cut down to painted surface.


27. Position new quarter glass on felt covered surface.
28. Apply cleaning solvent to sealing surface of glass and body flange.


CAUTION: Do not touch cleaned or primed areas with fingers.


29. Stick 4 self adhesive spacers on the inside edge of glass at corners.
30. Shake primer tins for at least 30 seconds. Apply body primer to sealing surface of body flange using supplied applicator.
31. Apply glass primer to sealing surface of glass.


CAUTION: Use a separate applicator for each primer.


32. Remove lid from sealer cartridge, remove crystals, pierce membrane and fit pre-cut nozzle. Fit cartridge to applicator gun.


NOTE: The profile of the nozzle must be modified slightly to produce the required bead section.


33. Apply a continuous bead of sealer to rear quarter glass as shown.







34. Fit suction lifters to glass.
35. With assistance, fit glass and align to body. Seat glass to spacer rubbers.
36. Remove protective tape.
37. Secure exterior trim to 'D' post with screws.
38. Connect aerial amplifier plug.
39. R.H. glass only: Connect alarm receiver plug.
40. Position headlining and engage beneath tailgate flip seal.
41. Secure headlining to 'E' posts with trim studs.
42. Fit exterior 'E' post finisher. Service and Repair
43. Fit grab handle.
44. Fit side interior lamp assembly. Service and Repair
45. Fit 'B' post upper trim. Service and Repair
46. Fit 'E' post trims. Service and Repair
47. Fit parcel tray support.


CAUTION: A curing time of 6 hours is recommended. During this time, leave the windows open and DO NOT slam the doors.