Back Window Glass: Service and Repair

Rear Window Removal and Installation

Removal

1. Tailgate Upper Trim Panel





1. Carefully pry out the notch (A) in the tailgate upper trim (B) with the appropriate trim tool to detach the hooks (C) and the tabs (D) from the tailgate side trims (E), and pull back the tailgate upper trim panel by hand to detach the clips (F), then remove the tailgate upper trim panel.

2. Tailgate Side Trim - Both Sides





1. Detach the hook (A) and the tabs (B) from the tailgate lower trim panel (C), and pull back the tailgate side trim (D) by hand to detach the clips (E), then remove the tailgate side trim.

2. Repeat this step on the opposite side.

3. Tailgate Lower Trim Panel





1. Remove the screw (A), then remove the tailgate pull pocket (B).





2. Pull out the tailgate lower trim panel (A) by hand to detach the clips (B, C), then remove the tailgate lower trim panel.

4. Rear License Trim





1. Remove the bolts (A).





2. Spray soapy water solution onto the double-sided adhesive tape (A), then carefully cut the adhesive tape along the lower edge of the rear license trim (B) with a utility knife while separating the trim from the tailgate (C) with a trim tool.

NOTE: Apply protective tape (D) around the cutting area as shown.





3. Pull out the rear license trim (A) with the appropriate trim tool to release the clip pins (B) from the clip grommets (C) on the tailgate, and detach the clips (D), then remove the rear license trim from the tailgate.

NOTE: The clip grommets will stay on the tailgate.





4. Remove the clip grommets (A) from the tailgate.

5. Install the clip grommets into the clip pins on the rear license trim.

NOTE: If the clip pins and the clip grommets are damaged or stress-whitened, replace them as an assembly with new ones.

5. Rear Window Wiper Arm Assembly





1. Raise the wiper arm (A) off the rear window, then remove the cover (B), the nut (C), and the wiper arm.

6. Rear Window Wiper Motor





1. Disconnect the connector.

2. Remove the rear window wiper motor (A).

7. Rear Window





1. Remove rubber dam (A, B) from the edges of the rear window (C). If necessary, cut the rubber dams with a utility knife.





2. Disconnect the connectors (A).





3. If the original rear window will be reinstalled, make alignment marks (A) across the glass and the body with a grease pencil.





Cutting positions





4. Apply protective tape along the inside and the outside edges of the tailgate. Make a hole with an awl through the adhesive from inside of the vehicle at the corner portion of the rear window. Push a piece of piano wire through the hole, and wrap each end around a piece of wood.

5. With a helper on the outside, pull the piano wire (A) back and forth in a sawing motion. Hold the piano wire as close to the rear window (B) as possible to prevent damage to the tailgate, and carefully cut through the adhesive (C) around the entire rear window.

6. Carefully remove the rear window.

Installation

1. Rear Window





1. Scrape smooth the original adhesive with a knife until there is a thickness of about 2 mm (0.08 in) on the bonding surface around the entire rear window opening flange:

* Do not scrape down to the painted surface of the body; damaged paint will interfere with proper bonding.
* Remove the fasteners or spacers from the tailgate.

2. Clean the body bonding surface with a shop towel dampened in isopropyl alcohol. After cleaning, keep oil, grease, and water from getting on the surface.

3. If you are reinstalling the original rear window, scrape off all of the original adhesive, the fasteners, the spacers (Css products), and the rubber dams from the rear window with a putty knife. Clean the bonding surface on the inside face and the edge of the rear window with isopropyl alcohol. Make sure the bonding surface is kept free of water, oil, and grease

4. Apply glass primer to the fasteners and the rubber dams mounting areas on the rear window, and let it dry. Attach rubber dam (A), the corner molding (B), rubber dams (C), rubber dam (D), and the fasteners (E, F) with the adhesive tape to the inside face of the rear window (G) as shown.

* Be sure the fasteners line up with alignment marks (H).
* Be careful not to touch the rear window where the adhesive will be applied.
* First attach the corner molding, then attach rubber dam (A) and rubber dams (C) around the edge of the rear window. Make sure edges of rubber dam (A) contact with the edges of the corner molding. If necessary, cut rubber dam (A) with a utility knife.
* Cut the excess rubber dam (C) along both beveled edges of the rear window.





5. Attach the fasteners (A, B) with adhesive tape to the tailgate as shown.





6. If you are installing a new rear window, set the rear window (A) in the opening, and center it. Make alignment marks (B) across the rear window and the body with a grease pencil at the four points shown. Make sure the pins (C) of both clips (D) contact with the holes of the tailgate corner. Be careful not to touch the rear window where the adhesive will be applied.

7. Remove the rear window.





8. Apply a light coat of glass primer to the rear window (A) along the edge of the rubber dams (B) and the corner molding as shown, then lightly wipe it off with gauze or cheesecloth:

* Apply the glass primer to the corner portions of the rear window using the printed dots (C) on the rear window as a guide.
* Do not apply body primer to the rear window, and do not mix up the body primer applicator and the glass primer applicator.
* Never touch the primed surfaces with your hands. If you do, the adhesive may not bond to the rear window properly, causing a leak after the rear window is installed.
* Keep water, dust, and abrasive materials away from the primed surface.





9. Carefully apply a light coat of body primer to any exposed paint or metal around the flange where the adhesive will be applied. Let the body primer dry for at least 10 minutes:

* Do not apply body primer to any remaining original adhesive on the flange.
* Do not mix up the body primer applicator and the glass primer applicator.
* Never touch the primed surfaces with your hands.





10. Cut a "V" in the end of the nozzle (A) on the adhesive cartridge as shown.





11. Put the cartridge in a caulking gun, and run a continuous bead of the adhesive (A) around the rear window (B) along the edge of the rubber dams (C) as shown:

* Use the printed dots (D) as a guide when you apply the adhesive to the corners of the rear window.
* Apply the adhesive within 30 minutes after applying the glass primer. Make a slightly thicker bead at each corner.

12. Hold the rear window with suction cups over the opening, align it with the alignment marks, and set it down on the adhesive. Lightly push on the rear window until its edges are fully seated on the adhesive all the way around.

NOTE: Do not open or close any of the doors for about an hour until the adhesive is dry.

13. Remove the excess adhesive with a putty knife or a shop towel dampened with isopropyl alcohol.

14. Wait at least an hour for the adhesive to dry, then spray water over the rear window and check for leaks. Mark the leaking areas, let the rear window dry, then seal with sealant. Let the vehicle stand for at least 4 hours after rear window installation. If the vehicle has to be used within the first 4 hours, it must be driven slowly.

15. Advise the customer not to do the following things for 2 to 3 days:

* Slam the doors with all the windows rolled up.
* Twist the body excessively (such as when going in and out of driveways at an angle or driving over rough, uneven roads).





16. Connect the connectors (A).

2. Rear Window Wiper Motor





1. Align the position marks when installing the seal (A), then install the washer (B) and rear window motor (C).

2. Connect the connector.

NOTE: Before reinstalling the rear wiper arm, turn the rear window wiper switch ON, then OFF to return the wiper shaft to the park position.

3. Rear Window Wiper Arm Assembly





1. Install the wiper arm (A), the nut (B), and the cover (C).

4. Rear License Trim

1. If you are reusing the original rear license trim (A), apply PP primer to the areas where new double-sided adhesive tapes (B) will be applied, then attach the new double-sided adhesive tapes to the trim as shown.











2. Fold the edge of each adhesive backing from the double-sided adhesive tape.





3. Hold up the rear license trim (A), and fit the clips (B, C, D) into the holes in the tailgate. Push on the trim until the clips snap into place securely.





4. Install the bolts (A).

5. Tailgate Lower Trim Panel





1. Hold up the tailgate lower trim panel (A), and fit the clips into the holes in the tailgate.

2. Push on the trim until the clips (B, C) securely snap into place.





3. Install the tailgate pull pocket (A), then install the screw (B).

6. Tailgate Side Trim - Both Sides





1. Install the tailgate side trim (A). Make sure the hook (B), the tabs (C), and the clips (D) snap into place securely.

2. Repeat this step on the opposite side.

7. Tailgate Upper Trim Panel





1. Install the tailgate upper trim panel (A). Make sure the hooks (B), the tabs (C), and the clips (D) snap into place securely.

8. Rear Window Wiper Arm/Nozzle - Adjustment

NOTICE:
* Adjust the washer nozzle by gently gripping, and then moving, the outside of the nozzle (A).
* Do not insert tools into the nozzle hole (B), as it may cause the washer fluid to spray incorrectly.

Wiper Arm Park Position

1. Turn the ignition switch to ON (II), then turn the wiper switch ON, and then back OFF.






2. When the wiper arm stops at the auto-stop position, make sure that it is at the correct position:

a: Wiper arm stop position on the rear window defogger.

Washer Nozzle Position

3. When you turn on the washer, make sure 50% or more of the washer fluid lands within the spray area. If the spray area is not within the standard positions, adjust the nozzle:

b: Position at about 108.5 mm (4.27 in) from the rear window center line (C).

c: Position at about 21.2 mm (0.83 in) from the top of the black ceramic area (D).

d: Position at about 21.9 mm (0.86 in) from the position (c).

9. Water Leak Test




Check for water leaks. Run water over the roof and on the sealing area as shown, and note these items:
* Use a 12 mm (0.47 in) diameter hose (A).
* Adjust the rate of water flow as shown.
* Do not use a nozzle.
* Hold the hose about 300 mm (12 in) away from the door.