Stationary Windows Page 1A6–1
Page 1A6–1
Section 1A6
Stationary Windows
ATTENTION
Before performing any service operation or other procedure described in this Section, refer to Section 00
Warnings, Cautions And Notes for correct workshop practices with regard to safety and/or property damage.
1 General Information ...............................................................................................................................2
2 Leak Correction, Bonded Windows......................................................................................................3
2.1 Minor Water Leak Correction................................................................................................................................ 3
3 Service Operations – Front ...................................................................................................................4
3.1 Windshield Assembly............................................................................................................................................ 4
Description............................................................................................................................................................. 4
Preparation............................................................................................................................................................. 5
Remove................................................................................................................................................................... 5
Reinstall – Short Method....................................................................................................................................... 7
Description ......................................................................................................................................................... 7
Preparation......................................................................................................................................................... 7
Reinstall ............................................................................................................................................................. 8
Reinstall – Long Method ..................................................................................................................................... 11
Description ....................................................................................................................................................... 11
Preparation....................................................................................................................................................... 12
Reinstall ........................................................................................................................................................... 13
4 Service Operations – Side...................................................................................................................17
4.1 Quarter Window Assembly................................................................................................................................. 17
Preparation........................................................................................................................................................... 17
Remove................................................................................................................................................................. 17
Reinstall................................................................................................................................................................ 19
5 Service Operations – Rear...................................................................................................................20
5.1 Rear Window Assembly...................................................................................................................................... 20
Description........................................................................................................................................................... 20
Preparation........................................................................................................................................................... 20
Remove................................................................................................................................................................. 21
Reinstall – Short Method..................................................................................................................................... 23
Description ....................................................................................................................................................... 23
Preparation....................................................................................................................................................... 23
Reinstall ........................................................................................................................................................... 24
Reinstall – Long Method ..................................................................................................................................... 26
Description ....................................................................................................................................................... 26
Preparation....................................................................................................................................................... 27
Reinstall ........................................................................................................................................................... 28
5.2 Rear Window Lower Finisher .............................................................................................................................. 31
Remove................................................................................................................................................................. 31
Reinstall................................................................................................................................................................ 31
6 Special Tools ........................................................................................................................................32
7 Torque Wrench Specifications............................................................................................................33
Techline
Stationary Windows Page 1A6–2
Page 1A6–2
1 General Information
The windshield plays an important role in
occupant protection by supporting the
passenger airbag during deployment.
Therefore, it is imperative the procedures in
this Section are correctly followed, as
incorrect installation may lead to injury or
death.
This Section describes the procedures to remove and reinstall the windshield assembly, rear window assembly, rear
window lower finisher and quarter window. Also described is a procedure to repair minor leaks to urethane bonded
windows.
The w i nd s h ie l d as se mb l y i s ma n u fa c t ur e d fr om l a mi n a ted g lass and h a s a ti n te d up per ba n d . Toughened safety glass is
used for all other windows.
The windshield assembly, rear wi n d ow ass e m b ly and li f t g a te windo w assembly a r e bonded to the vehicle body window
opening with ure th ane adhesive.
The quarter window assembl y is attached to the vehicle using plastic nuts. A self adhesive foam weatherstrip is affixed to
the glass to seal the windo w opening. The nuts should be replaced after removal to maintain an effective weather seal.
The rear window is surrounde d by a one-piece rubber weatherstrip. The join is on the v ertical centre lin e at the base of
the window assembly.
A moulded plastic finisher is fitted between the rear window weatherstrip and the rear compartment lid weatherstrip.
For replacement of urethane bon de d windows, urethane service ki ts have been dev eloped and must be used to maintain
original installation requirem ents. Two different installation methods can be used when replacing the windshield
assembly or rear window assembly:
• Short Method: involves partial removal of the urethane. It is to be used when the original urethane remaining o n the
window opening flanges after the window removal can be used as a base for the new window. This method would
be used where replacement of cracked windshields or removal of intact windo ws is required. The amount of
urethane left in the window openi ng can be controlled duri ng window removal. It is recommend to leave the
maximum amount of original urethane intact on the body opening flange.
• Long Method: involves complete removal of the urethane. It is to be used when the original urethane remaining on
the window opening flanges af ter the window removal cannot serve as a base for t he replacement window. This
method would be used in cas es nee ding metal work and / or paint refinishing in the window opening or in cases
where the window has been pr eviously replaced using the s hort method. In such instances, the build up of
urethane could position the window too high in the body opening. In these cases, the original urethane must be
completely removed and replac ed with new urethane follo wing the long me thod window installation.
The windshield and rear window are structural members of the vehicle. Once the urethane adhesive cures, they aid
vehicle rigidity.
For service procedures related to the rear door fixed window, refer to Section 1A5 Front and Rear Assemblies.
Stationary Windows Page 1A6–3
Page 1A6–3
2 Leak Correction, Bonded
Windows
LT Section No. — 11–020
Safety glasses an d work glo ves must be w orn
at all times when operating with glass.
NOTE
Only use urethane adhesive Betaseal 15685 or
equivalent for water leak correction on bonded
windows.
2.1 Minor Water Leak Correction
1 Secure protective covering with masking tape adjacent
to the suspect leak area
2 To determine the precise loc ation of the leak, use the
air and soap bubble leak test. T he soap and water
solution can be applied with either a spray applicator
or brush.
Figure 1A6 – 1
3 Place an air-hose nozzle on the inside of the
windshield or rear window assembly. Have an
assistant outside the vehicle apply a soapy water
solution opposit e the air source. As a low air pressure
(60 kPa) is applied, soap bubbles will form on the
outside of the window, indicating the location of the
leak.
4 If the suspect leak area is not obvious, commence the
testing across the top and down the sides until the
leak location has been determined.
5 Using a spatula, work fresh urethane such a s Betaseal
15685 or equivalent, in and around the leak area.
NOTE
It is only necessary to remove dust and foreign
matter, as water activates the curing process of
urethane.
6 Leak test the repair, using the air and soap bubble
leak test or apply a moderate spray of water.
7 Remove the masking tape and protective covers, then
clean the windo w assembly a nd adjacent paint and
trim surfaces.
Figure 1A6 – 2
Stationary Windows Page 1A6–4
Page 1A6–4
3 Service Operations – Front
3.1 Windshield Assembly
LT Section No. — 11–020
Safety glasses an d work glo ves must be w orn
at all times when operating with glass.
The windshield plays an important role in
occupant protection by supporting the
passenger airbag during deployment. It is
imperative the procedures in this Section for
replacing bonded windows are followed.
Incorrect installation may lead to injury or
death.
Care should be taken to ensure the
windshield does not strike the windshield
opening or any other object. Chipped edges
can lead to subsequent breakage of the
windshield.
NOTE
• Only use urethane adh esive such as Betaseal
15685 or equivalent.
• Skinning (partial curing) of the urethane
commences after exposure to the
atmosphere. At 23 degrees Celsius and 50
percent relative humidity, skinning
commences after 30 minutes. Complete
curing of the urethane at this temperature an d
humidity takes 72 hours.
• Urethane service kits are available from most
windshield agents. Manufacturer’s instruction s
should always be foll owed.
• Window assemblies should be installed in the
window opening within five minutes of the
application of urethane.
Description
The windshield assembly rem oval procedure is the same for both the short and long installation methods, with one
exception. If the short method installation is to be used, care must be taken during the windshield removal to ensure that
an even surface of the original remaining urethane exists in the body opening. This is required to serve as a base for the
new urethane bea d and the replacement windshield.
Stationary Windows Page 1A6–5
Page 1A6–5
Preparation
Prevent damage to the paint finish and
minimise clean up by using protective covers
and masking tape over the regions adjacent
to the windshield.
As required, remove the following compo nents:
1 Windshield wiper arm assembly and plenum cover assembly, refer to Section 12N Wipers, Washers and Horn.
2 Instrument panel end cap covers, and the windshield defroster grille assembly,
refer to Section 1A3 Instrument Panel and Consol e.
3 Windshield side garnish, refer to Section 1A8 Headlining and Interior Trim.
4 Internal rear-view mirror, refer to Section 12H Rear-view Mirrors.
Remove
NOTE
• All vehicles have a keyless entry control
module installed between the left and right-
hand windshield defroster grille assembly on
the instrument panel. It is not necessary to
remove the module, however take care to
avoid damage to it during windshield removal.
• To remove the windshield or rear window
special tool J36020 is required. Alternately
manufacture an equivalent tool. Refer to
6 Special Tools.
1 Remove the windshield reve al moulding (1) by pulling
the moulding from the windshield opening (2) . Start at
the lower corner (3) and work around the windshield.
2 If the windshield is broken, take care to remove all
fragments of glass from the windshield opening.
Ensure the headlining and other trim items
are not damaged while cutting the urethane.
3 Use special tool J36020, or equiv alent, thread one end
of the piano wire through the urethan e, starting at the
windshield upper corner. Pull the end of the piano wire
through with pliers.
Figure 1A6 – 3
4 Connect the end of the piano wire to the other han dle of the special tool or equivale nt.
5 With the aid of an assistant, commence cutting the urethane bead. Keep the outsi de handle (1) parallel to the edge
of the windshield. Use the full len gth of the wire to prevent heat build up in the wire, refer to Figure 1A6 – 4.
Stationary Windows Page 1A6–6
Page 1A6–6
NOTE
To minimise the damage to the interior of the
vehicle, the operator inside th e vehicle should act
as an anchor point and hold the T-handle as
close as possible to the windshield at all times
(especially along the lower edge of the
windshield). The outside operator should pull the
wire up to the interior T-handle in a walking
motion.
Figure 1A6 – 4
6 Carefully lift the windshield o ut of the bod y opening. If there is evidence of the windshield adhering to the urethane,
cut the area again with the piano wire.
7 Remove the two windshield locators from the windshield reinforcing flange , refer to Figure 1A6 – 5. Retain for
reinstallation of the windshield.
8 If the original windshield is to be insta lled again, place the windshield on a clean protected surface or a holding
fixture.
NOTE
• The use of suction cu ps will greatly assist an y
handling of the windshield.
• All traces of urethane must be removed from
the windshield. It is not necessary to remove
all traces of the original urethane from the
body opening, unless the long method of
reinstallation is being used. However, any
original urethane remaining must be smooth
and firm.
Stationary Windows Page 1A6–7
Page 1A6–7
Reinstall – Short Method
Description
Throughout the curing period, ensure the
door windows are partially lowered to
eliminate pressure build-up which can be
caused by slamming doors. A curing time of
24 hours is recommended, although the
vehicle may be driven after five hours
providing it is driven only on a smooth road at
speeds not exceeding 80 km/h with the door
windows partially lowered.
• The short method is recommended when replacing a cracked or broken windshield, or a leak condition that cannot
be overcome by using minor water le ak repair procedures.
• The short method installation i nvolves leaving the maximum amount of the original urethane intact on the body
opening to form a sound base for the replacement urethane and windshield. Any original urethane remaining must
be smooth and firm.
• If material other than urethane has been used for previous servicing of the windshield, the long method installation
procedure (complete removal of adhesive) is mandatory to achieve an effective window to metal bond.
Preparation
Care should be taken to ensure the
windshield does not strike the windshield
opening or any other object. Chipped edges
can lead to subsequent breakage of the
windshield.
Do not use petro leum based sol vents to clean
any part of the window assembly or body
opening as the presence of oil in the solvent
will pre vent th e adhesion of the n ew urethane.
1 Use a sharp scraper to carefully remove an y origina l urethane from around the windshield. Clean the windshield to
be installed with a suitable o il free cleaning agent.
Stationary Windows Page 1A6–8
Page 1A6–8
2 Check for correct alignment of the windshield by
temporarily pla c ing the windshield in the body
opening. Fit the windshield locator (1) between the
lower windshield edge (2) and the reinforcing flange
(3).
3 Ensure the windshield is centralised in the body
opening left to right by checking the gaps between the
windshield and body opening are eve n on both sides
of the vehicle.
4 With masking tape (4), mark the outer top and side of
the windshield pillar and the roof.
NOTE
This procedure will assist in the alignment of the
windshield in the correct horizontal and vertical
plane during final windshield installation.
5 Remove and place the windshield face down on a
clean protected surface or fixture.
Figure 1A6 – 5
Reinstall
Do not use petro leum based sol vents to clean
any part of the window assembly, or body
opening as the presence of oil in the solvent
will pre vent th e adhesion of the n ew urethane.
1 Thoroughly clean the inner surface and edges of the
windshield to which the ur ethane is to be applied. Use
a clean lint-free cloth and a suitable oil free cleaning
solvent.
2 Apply a 50 mm wide layer of clear glass primer, to the
inner surface of the windshield's perimeter.
Immediately wipe off with a lint-free cloth.
Figure 1A6 – 6
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Page 1A6–9
3 Check the condition of the windshiel d reveal moulding
assembly (1). Discard and replace with a new
moulding if damaged.
4 Fit the moulding to the sides and upper section of the
windshield. Ensure the notch of the moulding (2) is
aligned with the V locating mark (3) on the lower
portion of the right-hand and the left-hand side of the
windshield.
5 Check the condition of the original urethane around
the windshield opening flange for voids or looseness.
6 Cut away any loose pieces of urethane.
7 Using a suitable spatula, spre ad fresh urethane
smoothly into any voids or uneven sections.
Figure 1A6 – 7
8 Referring to Figure 1A6 – 8, apply a 20 mm wide strip of black glass primer (1) with the app licator (9) included in
the service kit to the inside of the windshield along:
• The upper edge (2), adjacent to the moulding (4).
• The side edges (3), adjacent to the mould in g.
• The lower edge 35 mm from the bottom edge (5) of the windshield. Do not apply primer a cross the gap for
displaying the Vehicle Identification Number (VIN) (8). Here apply the primer (6) 15 mm from the lower edge
of the windshield (7).
Figure 1A6 – 8
9 For ease of installation and to avoid unnecessary stress on the freshly appli ed urethane, it is recommended the
interior mirror assembly be fitted to the windshiel d prior to installation of the windshield to the vehicle,
refer to Section 12H Rear-view Mirrors.
Stationary Windows Page 1A6–10
Page 1A6–10
On the lower section of the body opening,
care must be taken to ensure the urethane
bead diameter is such that when compressed
by the windshield installation, the Vehicle
Identification Number (VIN) plate is not
obscured.
10 Use a hand or automatic applicator to apply a smooth and contin uous bead of urethane (1) to the inside of the
windshield (2).
Apply the urethane bead along:
• The upper edge, adjacent to the moulding.
• The side edges, adjacent to the moulding.
• The bottom edge (4) 35 mm inboard from the edge. Adjacent to the gap to display the VIN plate (6) apply a
suitably reduced amount of urethane (5) to ensure the VIN is not obscured when the windshield is installed.
Here apply the urethane 15 mm from the lower edge of the windshield.
The amount of new urethane applied should ensure the total amount of uret hane is within the recommended
dimensions. Refer to Figure 1A6 – 9.
NOTE
• Only use urethane adh esive such as Betaseal
15685 or equivalent.
• In cold weather, placing the urethane
cartridges adjacent to a source of warmth will
assist in the flow of urethane when using a
hand applicator.
Figure 1A6 – 9
Stationary Windows Page 1A6–11
Page 1A6–11
11 With the aid of an assistant, install the windshield
using the previously attached masking tape (1) on the
roof and windshield pi llar as a guide. Use a windshield
locator (2), between the lower windshield edge (3) and
the reinforcing flange (4), t wo places, to locate the
windshield verticall y i n the windshield opening.
12 Press the windshield firmly into positi on.
13 Check the effectiveness of sealing from inside the
vehicle. Should any gaps in the sealing exist, apply
additional urethane to fill these gaps.
Do not direct a heavy stream of water onto
freshly applied urethane. If a water leak is
evident, apply addition al urethane to the leak
area, using a spatula to work the urethane
into the source of the leak.
14 Wait two hours and then water test the windshield
using a moderate spray of water.
15 Clean off any excess urethane using Prepsol or white
spirit.
16 Clean the windshield and then remove the masking
tape previously installed.
17 Reinstall the trim and hardware as required.
Figure 1A6 – 10
Reinstall – Long Method
Description
Throughout the curing period, ensure the
door windows are partially lowered to
eliminate pressure build-up, which can be
caused by slamming doors. A curing time of
24 hours is recommended, although the
vehicle may be driven after five hours
providing it is driven only on a smooth road at
speeds not exceeding 80 km/h with the door
windows partially lowered.
• The long method should be used on vehicles requiring metal or paint repair to the windshield opening or when the
original adhesive is compl etely removed and replaced with new urethane for the windshield installati on.
• This method for the windshield replacement is used when the original ur ethane adhesive material cannot serve as
a base for the replacement windsh ield.
• This method should also be u s ed when the windshield h as been previously replac ed using the short method. In
such instances, the build-up of urethane could position the windshield too high in the o pening.
Stationary Windows Page 1A6–12
Page 1A6–12
Preparation
Care should be taken to ensure the
windshield does not strike the windshield
opening or any other object. Chipped edges
can lead to subsequent breakage of the
windshield.
Do not use petro leum based sol vents to clean
any part of the window assembly or body
opening as the presence of oil in the solvent
will pre vent th e adhesion of the n ew urethane.
NOTE
Thoroughly check the windshield opening flange
for any irregularities before installing the
windshield.
1 Remove carefully, using a sha rp scraper all of the original urethane from around the windshield. Cle an the
windshield to be installed with a suitable oil free cleaning agent.
2 Remove carefully, using a knife or sharp scraper all the original urethane from around the entire perimete r of the
windshield opening flange. Take care to avoid the removal of paint when removi ng urethane from opening flange.
If any paintwork around the windshield
opening flange has been damaged, refinish
the paint before proceeding. Damaged paint
can lead to subsequent ru stin g.
3 Check for correct alignment of the windshield by
temporarily pla c ing the windshield in the body
opening. Fit the windshield locator (1) between the
lower windshield edge (2) and the reinforcing flange
(3).
4 Ensure the windshield is centralised in the body
opening left to right by checking the gaps between the
windshield and body opening are eve n on both sides
of the vehicle.
5 With masking tape (5), mark the outer top and side of
the windshield pillar and the roof.
NOTE
This procedure will assist in the alignment of the
windshield in the correct horizontal and vertical
plane during final windshield installation.
6 Remove and place the windshield face down on a
clean protected surface or fixture.
Figure 1A6 – 11
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Page 1A6–13
Reinstall
Do not use petro leum based sol vents to clean
any part of the window assembly, or body
opening as the presence of oil in the solvent
will pre vent th e adhesion of the n ew urethane.
NOTE
• Flange primer is not required if using the
recommended urethane adhesive Betaseal
15685.
• If using an equivalent to Betaseal 15685 refer
to technical data supplied by the supplier.
1 Only if required by the supplier of the urethane, apply
flange primer (1) to the region indicated.
2 Thoroughly clean the inner surface and edges of the
rear window assembly to which the urethane is to be
applied, using clean lint-free cloths and a suitable oil
free cleaning solvent.
Figure 1A6 – 12
3 Apply a 50 mm wide layer of clear glass primer, to the
inner surface of the windshield's perimeter.
Immediately wipe off with a lint-free cloth.
Figure 1A6 – 13
Stationary Windows Page 1A6–14
Page 1A6–14
4 Check the condition of the windshiel d reveal moulding
assembly (1). Discard and replace with a new
moulding if damaged.
5 Fit the moulding to the sides and upper section of the
windshield. Ensure the notch of the moulding (2) is
aligned with the V locating mark (3) on the lower
portion of the right-hand and the left-hand side of the
windshield.
Figure 1A6 – 14
6 Referring to Figure 1A6 – 15, apply a 20 mm wide strip of black glass primer (1) with the applicator (9) included in
the service kit to the inside of the windshield along:
• The upper edge (2), adjacent to the moulding. (4)
• The side edges (3), adjacent to the mould in g.
• The lower edge 35 mm from the bottom edge (5) of the windshield. Do not apply primer a cross the gap for
displaying the Vehicle Identification Number (VIN) (8). Here apply the primer (6) 15 mm from the lower edge
of the windshield (7).
Figure 1A6 – 15
Stationary Windows Page 1A6–15
Page 1A6–15
7 For ease of installation and to avoid unnecessary stress on the freshly appli ed urethane, it is recommended the
interior mirror assembly be fitted to the windshiel d prior to installation of the windshield to the vehicle,
refer to Section 12H Rear-view Mirrors.
On the lower section of the body opening,
care must be taken to ensure the urethane
bead diameter is such that when compressed
by the windshield installation, the Vehicle
Identification Number (VIN) plate is not
obscured.
8 Use a hand or automatic applicator to apply a smooth and contin uous bead of urethane (1) to the inside of the
windshield (2).
Apply the urethane bead along:
• The upper edge, adjacent to the moulding.
• The side edges, adjacent to the moulding.
• The bottom edge (4) 35 mm inboard from the edge (3). Adjacent to the gap to display the VIN plate (6) apply
a suitably reduced amount of urethane (5) to ensure the VIN is not obscured when the windshield is installed.
Here apply the urethane (5) 15 mm from the lower edge of the windshield
The amount of urethane applied should be within the recomm ended dimensions. Refer to Figure 1A6 – 16.
NOTE
• Only use urethane adh esive such as Betaseal
15685 or equivalent.
• In cold weather, placing the urethane
cartridges adjacent to a source of warmth will
assist in the flow of urethane when using a
hand applicator.
Figure 1A6 – 16
Stationary Windows Page 1A6–16
Page 1A6–16
9 With the aid of an assistant, install the windshield
using the previously attached masking tape (1) on the
roof and windshield pillar to ensure accurate
installation. Use a windshield locator (2), between the
lower windshield edge (3) and the reinforcing
flange (4), two places, to locate the windshield
vertically in the windshield opening.
10 Press the windshield firmly into positi on.
11 Check effectiveness of sealing from inside the vehicle.
Should any gaps in the seali ng exist, apply additional
urethane to fill these gaps.
Do not direct a heavy stream of water onto
freshly applied urethane. If a water leak is
evident, apply addition al urethane to the leak
area, using a spatula to work the urethane
into the source of the leak.
12 Wait two hours and then water test the windshield
using a moderate spray of water.
13 Clean off any excess urethane using Prepsol or white
spirit.
14 Clean the windshield and then remove the masking
tape previously installed.
15 Reinstall the trim and hardware as required.
Figure 1A6 – 17
Stationary Windows Page 1A6–17
Page 1A6–17
4 Service Operations – Side
4.1 Quarter Window Assembl y
LT Section No. — 11–030
Safety glasses an d work glo ves must be w orn
at all times when operating with glass.
Care must be taken during any operation
involving the side glass removal or
installation, to not exert any load on the
window. Failure to observe this may result in
damage to the window.
NOTE
To retain a watertight seal the following
component will require replacement when
performing this operation.
• Quarter window nut (five required)
Preparation
As required, remove the body lock pillar garnish, refer to Section 1A8 Headlining and Interior T r im.
Remove
1 Remove the screw (1), three places, from the rear
door opening and partiall y remove the rear section of
the door opening moulding (2 ), disengaging it from the
quarter window assembly tab (3).
Figure 1A6 – 18
Stationary Windows Page 1A6–18
Page 1A6–18
2 Remove the quarter window nut (1), five places, securing the quarter window assembly (2) to the body opening,
refer to Figure 1A6 – 19.
Take care when removing the quarter window
from the body opening the attaching pins are
clear of the outer body.
3 Carefully lift the window from the vehicle.
Figure 1A6 – 19
Legend
1 Quarter Window Nut (five places) 2 Quarter Window Assembly
Stationary Windows Page 1A6–19
Page 1A6–19
Reinstall
1 Ensure the seal is in sound condition.
2 Fit the quarter window into the body opening, ensuring the pins are correctly aligned i nto the holes in the body
opening.
NOTE
The quarter window nuts are encapsulated with a
wax sealer. It is recommended the nuts be
replaced once removed, however if this is not
possible apply a small amount of sealer to the
end of the thread.
3 Install new nuts attaching the quarter window to the body opening. Do not tighten.
4 Position the door opening mouldi ng and tighten the screws to the correct torque specification.
Door frame opening moulding attaching
screw torque specification...........................1.0 – 2.0 Nm
5 Tighten the quarter window nuts to the correct torque specification.
Quarter window assembly attaching
nut torque specification...............................1.0 – 3.0 Nm
6 Perform a water test of the window's sealing, using a moderate spray of water.
7 Reinstall the trim and hardware as required.
Stationary Windows Page 1A6–20
Page 1A6–20
5 Service Operations – Rear
5.1 Rear Window Assembly
LT Section No. — 11–020
Safety glasses an d work glo ves must be w orn
at all times when operating with glass.
Care must be taken during any operation
involving the rear window assembly removal
or installation not to exert any load on the
window. Failure to observe this may result in
damage to the window.
NOTE
• Only use urethane adh esive such as Betaseal
15685 or equivalent.
• Skinning (partial curing) of the urethane
commences after exposure to the
atmosphere. At 23 degrees Celsius and 50
percent relative humidity, skinning
commences after 30 minutes. Complete
curing of the urethane at this temperature an d
humidity takes 72 hours.
• Urethane service kits are available from most
windshield agents. Manufacturer’s instruction s
should always be foll owed.
• Window assemblies should be installed in the
window opening within five minutes of the
application of urethane.
• The rear window moulding may require
replacement when performing this operation.
Description
The rear window assembly removal procedure is the same for both the sh ort and long installation methods, with one
exception. If the short method installation is to be used, care must be taken during removal to ensure that an even
surface of the original urethane remains in the body opening. This will serve as a base for the new urethane bead and
the replacement rear window.
Preparation
Prevent damage to the paint finish and
minimise clean up by using protective covers
and masking tape over the regions adjacent
to the rear window .
As required, remove the following compo nents:
1 Roof joint moulding, refer to Section 1A9 Exterior Ornamentation.
2 Body lock pillar garnish, refer to Section 1A8 Headlining and Interior Trim.
Stationary Windows Page 1A6–21
Page 1A6–21
Remove
A high mount stop lamp assembly is installed
below the rear window trim panel assembly.
Care must be taken to avoid damage to the
lamp assembly during window removal
procedure. It is not necessary to remove the
lamp assembly, but to ensure that it is clear of
any debris before window installation.
NOTE
To remove the windshield or rear window special
tool J36020 is required. Alternately manufacture
an equivalent tool. Refer to 6 Special Tools.
1 Disconnect the rear window electrical demister connectors and ce llular telephone antenna if fitted.
2 If the rear window is broken, carefully remove all fragments of glass from the window opening.
Ensure the headlining and other trim items
are not damaged while cutting the urethane.
3 Use special tool J36020, or equiv ale nt, thread one end of the piano wire throu gh the urethane, starting at the rear
window upper corner. Pull the end of the wire through with pliers.
4 Connect the end of the piano wire to the other han dle of the special tool or equivale nt.
5 With the aid of an assistant commence cutting the urethane bead. Keep the outside handle (1) parallel to the edge
of the rear window. Use the full length of the wire to prevent heat build up in the wire, refer to Figure 1A6 – 20.
NOTE
To minimise damage to the interior of the vehicle,
the operator inside the vehicle should act as an
anchor point, holding the T-handle as close as
possible to the window at all times. The outside
operator pulls the wire up to the interior T-handle
in a walking motion.
Stationary Windows Page 1A6–22
Page 1A6–22
Figure 1A6 – 20
6 Carefully lift the rear window out of the rear opening. If there is evidence of the window adhering to the urethane,
cut the area again with the piano wire.
7 If the original rear window is to be installed a gain, place the window on a clean protected surface or a holding
fixture.
NOTE
• The use of suction cu ps will greatly assist an y
handling of the rear windo w.
• All traces of urethane must be removed from
the rear window. It is not necessary to remo ve
all traces of the original urethane from the
body opening, unless the long method of
reinstallation is being used. However, any
original urethane remaining must be smooth
and firm.
Stationary Windows Page 1A6–23
Page 1A6–23
Reinstall – Short Method
Description
Throughout the curing period, ensure the
door windows are partially lowered to
eliminate pressure build-up, which can be
caused by slamming doors. A curing time of
24 hours is recommended, although the
vehicle may be driven after five hours
providing it is driven only on a smooth road at
speeds not exceeding 80 km/h with the door
windows partially lowered.
• The short method is recommende d when replacing a cracked or broken rear window, or a leak condition that
cannot be overcome by using minor water leak repair procedures.
• The short method installation i nvolves leaving the maximum amount of the original urethane intact on the body
opening to form a sound base for the replacement urethane and rear window. Any original urethane remaining
must be smooth and firm.
• If material other than urethane has been used for previous servicing of the rear window, the long method
installation procedure (complete removal of adhesive) is mandator y to ac hieve an effective window to metal bond.
Preparation
Care should be taken to ensure the rear
window does not strike the rear window
opening or any other object. Chipped edges
can lead to subsequent breakage of the rear
window.
Do not use petro leum based sol vents to clean
any part of the window assembly or body
opening as the presence of oil in the solvent
will pre vent th e adhesion of the n ew urethane.
1 Using a sharp scraper, carefully remove all the original urethane from around the rear window. Clean the rear
window to be installed with a suitable oil free cleaning agent.
2 Check for correct alignment of the rear window by temporarily placing the rear windo w in the body opening.
3 Ensure the rear windo w is centralised in the body opening left to right by checking the gaps between the rear
window and body opening are even on both sides of the vehicle.
4 Use masking tape (1), to mark the outer top of the roof
and the rear quarter panel.
NOTE
This procedure will assist in the alignment of the
window in the correct horizontal and vertical
plane during final window installation.
5 Remove and place the rear window assembly face
down on a clean protected s urface or fixture.
Figure 1A6 – 21
Stationary Windows Page 1A6–24
Page 1A6–24
Reinstall
Do not use petro leum based sol vents to clean
the rear w indow assembly or th e rear openin g
flange as the presenc e of t he o il in th e sol vent
will pre vent th e adhesion of the n ew urethane.
1 As required, remove the rear window moulding.
2 Thoroughly clean the inner surface and edges of the rear window assembly to which the urethane is to be applied,
using clean lint-free cloths and a suitable oil free cleaning s olve nt.
3 Apply a 50 mm wide layer of clear glass primer, to the
inner surface of the rear window's perimeter.
Immediately wipe off with a lint-free cloth.
4 If using an existing rear windo w moul ding, check its
condition. If damaged discard and replace it.
Figure 1A6 – 22
5 Install the rear window moulding (1) over the edge of the window. Ensure the moulding is fitted correctly to the
glass with the moulding joint at the bottom middle (2) of the rear window, refer to Figure 1A6 – 23.
6 Check the condition of the original urethan e around the window opening flange for voids or looseness and cut away
any loose pieces.
7 Using a suitable spatula, spread fresh urethane smoothly into any voids or uneven sections.
8 Apply a 20 mm wide strip of black glass primer (4) with the applicator (3) included in the service kit adjacent to the
inside edge of the window moulding (1).
9 Use a hand or automatic applicator to appl y a smooth and continuo us bead of urethane (5) to the inside of the rear
window adjacent to the inside edge of the window moulding (1). The amount of new urethane applied should
ensure the total amount of urethane is within the recommended dimensions.
NOTE
• Only use urethane adh esive such as Betaseal
15685 or equivalent.
• In cold weather, placing the cartridges
adjacent to a source of warmth will assist in
the flow of urethane when using a hand
applicator.
Stationary Windows Page 1A6–25
Page 1A6–25
Figure 1A6 – 23
Legend
1 Moulding
2 Moulding Joint Position (on centre-line)
3 Applicator
4 Black Glass Primer
5 Urethane Adhesive
Stationary Windows Page 1A6–26
Page 1A6–26
10 With the aid of an assistant, install the rear window
assembly using the previously attached masking tape
(1) on the roof and the rear quarter panel as a guide.
NOTE
Ensure the rear window is centralised in the
body opening left to right by checking the gaps
between the windo w mouldin g an d body openin g
are even on both sides of the vehicl e.
11 Press the rear window firmly into position.
12 Check the effectiveness of sealing from inside the
vehicle. Should any gaps in the sealing exist, apply
additional urethane to fill these gaps. Figure 1A6 – 24
Do not direct a heavy stream of water onto
freshly applied urethane. If a water leak is
evident, apply additional urethane to the leak
area, using a spatula to work the urethane
into the source of the leak.
13 Wait two hours and then water test the rear window using a moderate spray of water.
14 Clean off any excess urethane using Prepsol or white spirit. Clean the rear window and then remove the masking
tape previously installed.
15 Connect the electrical demist connectors and cell ular telephone antenna if fitted.
16 Reinstall the trim and hardware as required.
Reinstall – Long Method
Description
Throughout the curing period ensure the door
windows are partially lowered to eliminate
pressure build-up, which can be caused by
slamming doors. A curing time of 24 hours is
recommended, although the vehicle may be
driven after five hours providing it is driven
only on a smooth road at speeds not
exceeding 80 km/h with the door windows
partially lowered.
• The long method should be used on vehicles requiring metal or paint repair to the rear window opening, when the
original adhesive is completely removed and replaced with new urethane for the rear window installation.
• This method for the rear windo w replacement is used when the original urethane adh esive material cannot serve
as a base for the replacement rear window.
• This method is also used when the rear window has been previously replaced using the short method. In such
instances, the build-up of uret hane could position the rear window too high in the opening.
Stationary Windows Page 1A6–27
Page 1A6–27
Preparation
Care should be taken to ensure the rear
window does not strike the rear window
opening. Chipped edges can lead to
subsequent breakage of the window
assembly.
Do not use petro leum based sol vents to clean
the rear window or the rear o pening flange, as
the presence of the oil in the solvent will
prevent the adhesion of the new urethane.
NOTE
Thoroughly check the rear window opening
flange for any irregularities before installing the
rear window assembly.
1 Using a sharp scraper, carefully remove any original urethane from around the rear window. Clean the window to
be installed with a suitable o il free cleaning agent.
2 Using a knife or sharp scraper, remove the original urethane from around the entire perimeter of the windo w
opening flange. Take care to avoid the removal of paint when removing urethane from opening flange.
If any paintwork around the rear window
opening flange has been damaged, refinish
the paint before proceeding. Damaged paint
can lead to subsequent ru stin g.
3 Check for correct alignment of the rear window by temporarily placing the rear windo w in the body opening.
4 Ensure the rear windo w is centralised in the body opening left to right by checking the gaps between the rear
window and body opening are even on both sides of the vehicle.
5 With masking tape (1), mark the outer top of the roof
and the rear quarter panel.
NOTE
This procedure will assist in the alignment of the
window in the correct horizontal and vertical
plane during final window installation.
6 Remove and place the rear window assembly face
down on a clean protected s urface or fixture.
Figure 1A6 – 25
Stationary Windows Page 1A6–28
Page 1A6–28
Reinstall
Do not use petro leum based sol vents to clean
the rear window assembly, or the rear
opening flange as the presence of the oil in
the solvent will prevent the adhesion of the
new urethane.
NOTE
• Flange primer is not required if using the
recommended urethane adhesive Betaseal
15685.
• If using an equivalent to Betaseal 15685 refer
to technical data supplied by the supplier.
1 Only if required by the supplier of the urethane, apply
flange primer (1) to the region indicated.
2 If required remove the rear window moulding.
3 Thoroughly clean the inner surface and edges of the
rear window assembly to which the urethane is to be
applied, using clean lint-free cloths and a suitable oil
free cleaning solvent.
Figure 1A6 – 26
4 Apply a 50 mm wide layer of clear glass primer, to the
inner surface of the rear window's perimeter.
Immediately wipe off with a lint-free cloth.
5 If using an existing rear windo w moul ding, check its
condition. If damaged discard and replace it.
Figure 1A6 – 27
6 Install the rear window moulding (1) over the edge of the window. Ensure the moulding is fitted correctly to the
window with the moulding joint at the bottom middle (2) of the rear window, refer to Figure 1A6 – 28.
Stationary Windows Page 1A6–29
Page 1A6–29
7 Apply a 20 mm wide strip of black glass primer (4) with the applicator (3) included in the service kit adjacent to the
inside edge of the windo w moulding (1).
8 Use a hand or automatic applicator to appl y a smooth and continuo us bead of urethane (5) to the inside of the rear
window adjacent to the inside edge of the window moulding (1). The amount of urethane applied sho uld be within
the recommended dimensions.
NOTE
• Only use urethane adh esive such as Betaseal
15685 or equivalent.
• In cold weather, placing the urethane
cartridges adjacent to a source of warmth will
assist in the flow of urethane when using a
hand applicator.
Figure 1A6 – 28
Legend
1 Moulding
2 Moulding Joint Position (on centre line)
3 Applicator
4 Black Glass Primer
5 Urethane Adhesive
Stationary Windows Page 1A6–30
Page 1A6–30
9 With the aid of an assistant, install the rear window
assembly, using the previously attached masking tape
(1) on the roof and the rear quarter panel as a guide.
NOTE
Ensure the rear window is centralised in the
body opening left to right by checking the gaps
between the window moulding and the body
opening are even on both sides of the vehicle.
10 Press the rear window firmly into position.
11 Check effectiveness of sealing from inside the vehicle.
Should any gaps in the seali ng exist, apply additional
urethane to fill these gaps. Figure 1A6 – 29
Do not direct a heavy stream of water onto
freshly applied urethane. If a water leak is
evident, apply additional urethane to the leak
area, using a spatula to work the urethane
into the source of the leak.
12 Wait two hours then water test the rear windo w, using a moderate spray of water.
13 Clean off any excess urethane using Prepsol or white spirit. Clean the rear window, then remove the masking tape
previously installed.
14 Connect the electrical demist connectors and cell ular telephone antenna if fitted.
15 Reinstall the trim and hardware as required.
Stationary Windows Page 1A6–31
Page 1A6–31
5.2 Rear Window Lower Finisher
Remove
1 Remove the rear compartment lid weatherstrip (1) from around the lip flan ge of the rear compartment (2), refer to
Figure 1A6 – 30.
2 Starting from one end, carefully remove the rear window lower finisher (3) by pulling it out from under the rear
window weatherstrip (4).
Figure 1A6 – 30
Reinstall
1 Gently lift the rear window weatherstrip using a fine bladed screwdriver and insert the lower finisher underneath it.
2 Reinstall the rear compartment lid weatherstrip on the lip flange around the rear compartment.
Stationary Windows Page 1A6–32
Page 1A6–32
6 Special Tools
Tool Number Illustration Description Tool Classification
J36020
Windshield Removal Tool and
Piano Wire
Previously Released
Unique
Alternative:
Manufacture an equivalent tool.
1 Manufacture two T-handles to the dimensions shown.
2 Thread 700 mm of piano wire through the hole of one
handle.
Figure 1A6 – 31
Stationary Windows Page 1A6–33
Page 1A6–33
7 Torque Wrench Specifications
Door Opening Moulding Retaining Screw......................................1.0 – 2.0 Nm
Quarter Window Assembly Retaining Nut .....................................1.0 – 3.0 Nm