Back Window Glass: Service and Repair
Removing And Installing Rear Window
Tools
Preliminary work
1. Remove C-pillar trim panel at the left and right. Refer to Removing and installing C-pillar trim.
2. Remove wiper motor for rear window washer. Refer to Removing and installing wiper motor for rear window washer.
3. Remove rear centre panel. Refer to Removing and installing rear centre panel.
General warning notes
- General information on installing and removing car windows
Tools and materials
The following tools and materials are required for removing and installing the rear window with 2-component adhesive:
Removing rear window
INFORMATION: The door windows must not be closed until after the curing time has elapsed.
1. Lower the door windows.
2. Pull off the plug for the rear window heater on the rear window.
3. Remove rear window with the cutting wire separator.
Preparing window aperture for installation
Removing adhesive from the body
INFORMATION: The surface coating of adhesive residue helps new adhesive to stick. Keep cut surfaces clean and free of grease and do not clean with cleaning solution.
1. When removing remaining adhesive -1- with the cutting tool -C- and the flashing knife -D- on the body, ensure that a surface coating of adhesive remains -2-.
Cleaning and priming paint damage or newly built-up paint areas in the window aperture of the body
INFORMATION: A ventilation period of at least 10 minutes must be observed between the cleaning of the glass section and the application of the primer. No cleaning solution residues may remain on the body.
1. Clean new paint areas or damage to the top coat paint in the non-visible area of the glass section in the body with cleaning solution -H1- and patch with primer -H2-.
Preparing rear window for installation
Removing seal for rear window
INFORMATION: Only if the window is to be re-installed.
1. Pull off seal -3-. Remove adhesive residues with cleaning solution -H1-.
Removing adhesive from the rear window
INFORMATION:
- Only if the rear window is to be re-installed.
- The remaining adhesive helps new adhesive to stick. Keep cut surfaces clean and free of grease and do not clean with cleaning solution.
1. Equip cutter -C- with flashing knife -D- and remove remaining adhesive from the rear window, ensuring that a surface coating of adhesive remains.
Fitting seal for rear window
1. Staring from the edge, adhere the seal -3- along the entire border of the rear window -4-.
Applying activator to the bonding section of the rear window
INFORMATION: Only if the rear window is to be re-installed.
1. During longer idle periods (> 24 h) apply activator -H3- to the remaining adhesive.
INFORMATION: A ventilation period of at least 10 minutes must be observed between the cleaning of the glass and the application of the primer. No cleaning solution residues may remain on the body.
2. Clean window with cleaning solution -H1-.
3. Apply primer -H2- to the window flange in the area of the marking.
Installing rear window
Aligning rear window
INFORMATION: Two persons are needed to insert and adjust the rear window.
1. Apply suction cups -B- to the rear window and insert the rear window into the window aperture.
INFORMATION: Ensure that the rear window can no longer be aligned after it is inserted.
2. Align the rear window in the Z and Y directions. Mark the rear window with adhesive tape and remove.
Preparing 2-component adhesive for processing
INFORMATION:
- The adhesive has an open time of -15 min-, which means that the bonding material must be applied and the car window must be assembled within this period of time.
- In order to ensure that the substance is completely mixed, apply a 30 mm long adhesive bead of fresh adhesive to a piece of cardboard before processing.
1. Preparing 2-component adhesive for processing.
Applying adhesive on the rear window
INFORMATION: When applying the adhesive, it is essential to ensure that the adhesive bead overlaps by approx. 30 mm at the beginning and at the end.
1. Using bonding gun -A- apply 2-component adhesive to the rear window along the seal -3- in the form of a triangular bead with the dimension -X= ca. 15 mm- -Y= ca. 8 mm-.
Pulling off protective film
INFORMATION: Make sure that no further work is performed in the area of the seal once the protective film has been removed.
1. Before gluing in the rear window, peel off the protective film on the seal without leaving residues.
Inserting rear window into the body
CAUTION: Danger of material damage if specified curing time of adhesive is not observed.
- There will not be a proper adhesive bond if the prescribed curing time of the adhesive is not observed.
- The vehicle must not be used until the curing time has elapsed.
- Curing time: 3 hours
- Temperature: at least 10°C
- Fixing time: approx. 1 hour
INFORMATION:
- Two persons are needed to insert and adjust the rear window.
- The rear window can no longer be aligned, because the bonding section on the seal immediately sticks to the body when the rear window is installed.
1. Insert the rear window into the window aperture and fit it at the previously marked positions.
Cleaning fields of vision
INFORMATION: The door windows must not be closed until after the curing time has elapsed.
1. Adhesive which has oozed out must be removed immediately and the affected fields of vision must be cleaned using cleaning agent -H1-.
Subsequent work
1. Connect plug connection for the rear window heater.
2. Install C-pillar trim panel at the left and right. Refer to Removing and installing C-pillar trim.
3. Install wiper motor for rear window washer. Refer to Removing and installing wiper motor for rear window washer.
4. Install rear centre panel. Refer to Removing and installing rear centre panel.
5. Close the door windows.