SECTION 1A6 - STATIONARY GLASS

CAUTION:

This vehicle will be equipped with a Supplemental Restraint System (SRS). A SRS will

consist of either seat belt pre-tensio ners and a driver’s side air bag , or seat belt pre-

tensioners and a driver’s and front passenger’s side air bags. Refer to CAUTIONS,

Section 12M, before performing any service operation on or around SRS

components, the steering mechanism or wiring. Failure to follow the CAUTIONS

could result in SRS deplo yment, resulting in possible p ersonal injury or unnecessary

SRS system repairs.

CAUTION:

This vehicle may be equipped with LPG (Liquefied Petroleum Gas). In the interests of

safety, the LPG fuel system should be isolated by turning 'OFF' the manual service

valve and then draining the LPG serv ice lines, before any service w ork is carried out

on the vehicle. Refer to the LPG leaflet included with the Owner's Handbook for

details or LPG Section 2 for more specific servicing information.

1. GENERAL DESCRIPTI ON

Three different installation methods are used when installing stationary glass to VT Series Models.

The windshield, which is laminated and features a tinted upper band, the rear window on sedans, the tailgate glass

on station wagons, both of which have electrically heated demist facility, are all bonded in the body apertures with

urethane adhesive.

The rear quarter windows on station wagons utilise a self adhesive foam weatherstrip to seal the glass to the body.

The station wagon rear quarter windows are secured to the body opening by plastic screw on nuts.

Toughened safety glass is used for all the windows except the windshield.

For replacement of urethane adhesive bonded glasses, urethane adhesive kits have been developed and must be

used to maintain original installation requirements. Glass installed with urethane requires either partial or complete

removal of the urethane adhesive when replacing the glass. Partial removal of the urethane adhesive is referred to

as the ‘short method’. Complete removal of the urethane is known as the ‘long method’.

The short method is used where original urethane adhesive left on body opening pinch weld flanges after glass

removal can serve as a base for the new glass. This method would be used in cases of replacement of cracked

windshields or removal of glass that is intact. The amount of urethane left in the glass opening can be controlled

during glass removal, leaving the maximum amount of original urethane intact on the body opening flange.

The long method is to be used when the original urethane left in the window opening after glass removal cannot

serve as a base for replacement glass. This method would be used in cases needing metal work or where paint

refinishing is required in the opening; or in cases where the glass has been previously replaced, using the short

method. In such instances, the build up of urethane could position the glass too high in the opening. In these cases,

the original urethane is completely removed and replaced with new urethane during glass installation.

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2. SERVICE NOTES

WARNING:

SAFET Y GLASSES AND WO RK GLOVES M UST BE

WORN AT ALL TIMES WHEN OPERATING WITH

GLASS.

NOTE:

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

and humidity takes 72 hours.

The tools recommended for cutting out the adhesive

bonded glasses are :

1. Piano wire and T handles - AU390.

2. FEIN Special Cutter, Model Astlxe 636-5.

3. Stationary glass removal kit.

These tools are available from Kent-Moore Tool &

Equipment Division of SPX Australia.

3. SERVICE OPERATIONS

3.1 WINDSHIELD GLASS

REMOVE

The windshield glass removal procedure is the

same for both the short and long installation

methods with one exception.

If the short method installation is to be used, more

care must be taken during glass rem oval to ensure

that an even surface of the original remaining

urethane exists in the body opening to serve as a

base for the new urethane bead and the

replacement glass.

The windshield moulding is installed over the edge

of the windshield glass and can be removed by

pulling the moulding from the windshield opening

starting at the windshield lower corner, after

removal of the components as detailed below.

Mouldings are available for service replacement.

Refer to VT Series parts Information for details.

Figure 1A6-1

CAUTION:

Care must be taken during any operation involving

windshield removal or installation not to exert any

load on the windshield glass. Failur e to obs erve this

may result in damage to the glass.

1. To prevent damage to paint f inis h and tr im and

to minimise clean up, mask-up and place

protective covers over parts adjacent to the

windshield.

2. Remove windshield wiper arm and blade

assemblies refer Fig. 1A6-1.

3. Remove six scrivets retaining both right and

left plenum covers.

Figure 1A6-2

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4. Remove ten scrivets retaining plenum water

deflector, pull deflector towards front of

vehicle, disengaging location tabs and remove

from vehicle, refer Fig. 1A6-3.

Figure 1A6-3

5. Remove windshield moulding cover by pulling

the moulding from the windshield opening,

starting at the windshield lower corner and

working around the opening.

Figure 1A6-4

6. Front inside vehicle, remove instrument panel

end cap cover right side and left side.

7. Remove the screws retaining the demist

nozzle right side and left side and remove the

demist nozzles. Refer to

Section 1A3, INSTRUMENT PANEL.

NOTE:

On all vehicles, care must be taken to avoid

damage to the sun sensor.

8. Remove interior mirror assembly by sliding

mirror base upwards.

9. Remove ‘A’ pillar trim assembly, refer to

Section 1A8, HEADLINING AND REAR END

TRIM.

Figure 1A6-5

10. Using piano wire and T-handles AU 390 or

equivalent (refer Fig. 1A6-6 for dimensions),

thread one end of the piano wire through the

urethane, starting at the windshield upper

corner, pulling the end of the wire through with

pliers.

NOTE:

Use at least 700mm of wire between the T-handles.

NOTE:

Ensure that the headlining and other trim items are

not damaged.

Figure 1A6-6

11. Connect the wire to the remaining T-handle

and with the aid of an assistant, commence

cutting the urethane bead, keeping the outside

T-handle parallel to the edge of the glass using

the full length of the wire to prevent heat build

up in the wire.

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 glass at all times, especially along

the lower edge of the windshield, while the out side

operator pulls the wire up to the interior T-handle in

a ‘walking’ motion refer Figs. 1A6-7, 1A6-8, 1A6-9,

and 1A6-10. Figure 1A6-7

Figure 1A6-8

Figure 1A6-9

Figure 1A6-10

12. Carefully lift the windshield out of the body

aperture. If there is evidenc e of glas s adher ing

to the urethane, re-cut the area with the piano

wire.

13. If the original windshield is to be reinstalled,

place the windshield on a clean protected

surface, holding fixture etc.

NOTE:

The use of suction cups will greatly assist any

handling of the windshield.

14. Using a sharp scraper, carefully remove any

original urethane from the windshield. Clean

the windshield with a suitable oil free cleaning

agent. If a new windshield is to be installed,

clean the windshield with a suitable oil free

cleaning agent.

WARNING:

Do not use petroleum based solvents to clean

the windshield or body opening flange as the

presence of oil will prevent adhesion of the

new urethane/silicon.

15 Correctly locate the windshield in the opening

then tape mark the outer top and side of the

windshield , pillar and roof, as illus tr ated in Fig.

1A6-11. This procedur e assis t the operators to

align the windshield in the correct horizontal

and vertical plane during final windshield

installation.

16. Remove and place the windshield face down

on a clean protected surface.

Figure 1A6-11

SHORT METHOD INSTALLATION

DESCRIPTION

Short method installation involves the maximum

amount of the original urethane being left intact on

the body opening to form a sound base for the

replacement adhesive and windshield.

This method is recommended when replacing a

cracked or broken windshield, or a leak condition

that cannot be overcome by using m inor water leak

repair procedures.

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

glass to metal bond.

REINSTALL

1. Thoroughly clean the inner s urface and edges

of the windshield which are to contac t the new

urethane, using clean c loths and a s uitable oil-

free cleaning solvent.

2. Apply clear glass primer to inner surface of

glass around the perimeter of the windshield

edge over the solid black c eramic pattern ( or a

width of 50 m m) and im m ediately wipe off with

a lint free rag.

Figure 1A6-12

3. Install locator windshield left side part No.

92078269 and locator windshield right side

part No. 92078270. Ensure locators are fitted

correctly to windshield glass and have a

clearance between side and top locators of

approx. 3 mm.

4. Install locator windshield upper part No.

92076026, ensure moulding is fitted correctly

to glass.

Figure 1A6-13

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5. Using the applicator included in the

replacement kit, apply glass primer (black)

around the upper and side perimeter of the

windshield edge and 7 mm inboard to the

inner surface as illustrated in Fig. 1A6-14. On

the lower edge, repeat the operation at a

distance of 35 mm from the edge of the glass

in a band 12 mm wide.

6. Check for voids or looseness in original

urethane. Cut away any loose pieces of

urethane and, using a suitable spatula, paddle

fresh urethane or silicon smoothly into any

voids.

7. Using a hand or automatic applicator, apply a

smooth continuous bead of urethane

adhesive, such as Betaseal 554.02 or

equivalent, between the centre and outer

edge, on top of original urethane and around

entire perimeter of the body opening. The

urethane bead should be a minimum of

10 mm in diameter.

Figure 1A6-14

NOTE:

Urethane service kits are available from most

windshield agents. Manufacturer's instructions

should always be followed.

IMPORTANT:

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 is not obscured.

NOTE:

In cold weather, the placement of cartridges

adjacent to a source of warmth will assist the flow

of urethane when using a hand applicator.

8. With the aid of an assistant, install the

windshield, using the previously attached

masking tape on the roof and windshield to

ensure accurate installation. Use wedges

placed at the lower windshield edge to locate

glass vertically in windshield opening. Press

windshield firmly into position.

9. Check effectiveness of seating from inside of

the vehicle. Should any gaps in the sealing

exist, apply additional urethane on the outside

to fill these gaps. Using a flat bladed tool,

sm ooth the surface of the ur ethane around the

edge on the outside of the windshield to

ensure effective sealing.

10. Water test the windshield, using a moderate

spray of water.

NOTE:

Do not direct a heavy stream of water onto freshly

applied urethane. If a water leak is evident, apply

additional urethane to the leal area, using a flat

bladed tool to work urethane into source of leak.

Figure 1A6-15

IMPORTANT:

If silicon is used for spot sealing, allow a minimum

of one (1) hour to permit the silicon to skin and

adhere to the original urethane, prior to water

testing the repair.

11. Clean off any excess urethane/silicon using

Prepsol or white spirit. Clean the windshield,

then remove the masking tape previously

installed.

12. Identify datum marks on rear edge of

windshield moulding cover. If damaged

replace windshield moulding cover.

Figure 1A6-16

13. Begin installing windshield moulding cover at

top drivers side corner of windshield. Align

datum mark on windshield moulding cover

with end of windshield locator, refer to Fig.

1A6-16.

14. Clip windshield moulding cover in place

around upper corner of windshield. Insert drive

side lower end of windshield moulding cover

loosely behind top of guard, attach m oulding to

driver side windshield locator, working from

upper corner to lower corner of windshield

refer Fig. 1A6-17 step 1.

15. Install upper windshield moulding cover,

working from driver side upper corner to

passenger side upper c orner refer Fig. 1A6-17

step 2.

16. Insert passenger side lower end of windshield

moulding cover loosely behind top of guard

then attach moulding to passenger side

windshield locator, working from upper corner

to lower cor ner of windshield re fer Fig. 1A6-17

step 3.

NOTE:

Ensure barbed retainer on windshield moulding

cover engages to retainer cavity in windshield

locator and not between windshield locator and

body panel, refer Fig. 1A6-17, Section A-A and B-

Figure 1A6-17

17. Reinstall plenum chamber water deflector,

right and left side plenum covers, and wiper

arm assemblies.

14. Reinstall interior mirror assembly.

NOTE:

Ensure that door windows are partially lowered to

eliminate pressure build up which can be caused

by slamming doors. A curing time of 24 hours is

recom mended, although the vehicle m ay be driven

after 5 hours, providing it is driven on a smooth

road at speeds not exceeding 80 km/h with door

windows partially lowered.

LONG METHOD INSTALLATION

DESCRIPTION

The long method replacement is used when

original urethane adhesive material cannot serve

as a base for the replacement windshield.

This method should be used on vehicles requiring

metal or paint repair to the windshield opening

when original adhesive is completely removed and

replaced with new urethane for windshield

installation.

This method is also used when the windshield has

been previously replaced, using the short method.

In such instances, the build-up of urethane could

position the windshield too high in the opening.

REMOVE

1. Remove the windshield (refer

3.1 WINDSHIELD GLASS in this section).

2. Using a knife or sharp scraper, remove the

original urethane from around the entire

perimeter of the windshield opening flange.

Body opening check

1. Thoroughly check the windshield body

opening flange for any irregularities before

installing the windshield.

NOTE:

It will be necessary to remove the windshield pillar

mouldings.

Refer Section 1A9 ‘HEADLINING & REAR END

TRIM’.

2. Use the windshield as a tem plate for check ing

correct alignment between the windshield and

body opening. If necessary, reform the body

opening flange to produce a uniform flange to

windshield contour.

CAUTION:

Care should be taken to ensure that glass does

not strike the windshield opening. Chipped

edges can lead to subsequent breakage of

glass.

3. Correctly locate the windshield in the opening

then tape mark the outer top and side of the

windshield , pillar and roof. This procedure

assist the operators to align the windshield in

the correct horizontal and vertical plane during

final windshield installation.

4. Remove and place the windshield face down

on a clean protected surface or fixture.

Figure 1A6-18

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REINSTALL

1. Using one of the applicators in the

replacement kit, apply flange primer to any

section of the windshield opening flange that

has been cleaned back to bare m etal or to the

painted. Allow this primer to dry for 15

minutes.

DO NOT TOUCH PRIMED SURFACES

NOTE:

If the windshield pillar mouldings have been

removed, reinstall or replace as necessary.

2. Thoroughly clean the inner surface and edges

of the windshield to which the urethane is to be

applied, using clean cloths and a suitable oil

free cleaning solvent. Figure 1A6-19

3. Apply clear glass primer to inner surface of

glass around the perimeter of the windshield

edge over the width of the solid black ceram ic

pattern (or a width of 50 m m) and imm ediately

wipe off with a lint free rag.

4. Install locator windshield upper part No.

92076026, ensure moulding is fitted correctly

to glass.

5. Install locator windshield left side part No.

92078269 and locator windshield right side

part No. 92078270. Ensure locators are fitted

correctly to windshield glass and have a

clearance between side and top locators of

approx. 3 mm. Figure 1A6-20

6. Using the applicator included in the

replacement kit, apply glass primer (black)

around the upper and side perimeter of the

windshield edge and 7 mm inboard to the

inner surface. On the lower edge, repeat the

operation at a distance of 35 mm from the

edge of the glass in a band 12 mm wide.

Figure 1A6-21

7. Using a hand or automatic applicator, apply a

smooth continuous bead of urethane

adhesive, such as Betaseal 554.02 or

equivalent, between the centre and outer

edge, on top of original urethane and around

entire perimeter of the body opening. The

urethane bead dimensions should be as

shown in Fig. 1A6-22.

NOTE:

Urethane service kits are available from most

windshield agents around Aus tralia. Manufac turer’s

instructions should always be followed.

Figure 1A6-22

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IMPORTANT:

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 is not obscured.

NOTE:

In cold weather, the placement of cartridges

adjacent to a source of warmth will assist the flow

of urethane when using a hand applicator.

8. With the aid of an assistant, install the

windshield, using the previously attached

masking tape on the roof and windshield to

ensure accurate installation. Use wedges

placed at the lower windshield edge to locate

glass vertically in the windshield opening.

Press windshield firmly into position.

9. Check effectiveness of sealing from inside of

the vehicle. Should any gaps in the sealing

exist, apply additional urethane on the outside

to fill these gaps. Using a flat bladed tool,

sm ooth the surface of the ur ethane around the

edge on the outside of the windshield to

ensure effective sealing.

10. Water test the windshield, using a moderate

spray of water.

NOTE:

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 flat

bladed tool to work urethane into source of leak.

IMPORTANT:

If silicon is used for spot sealing, allow a minimum

of one (1) hour to permit the silicon to skin and

adhere to the original urethane prior to water

testing the repair.

11. Clean off any excess urethane/silicon using

Prepsol or white spirit. Clean the windshield,

then remove the masking tape previously

installed.

12. Reinstall the windshield moulding cover , and if

damaged, new windshield moulding cover.

13. Reinstall plenum chamber water deflector,

right and left side plenum covers, and wiper

arm assemblies.

14. Reinstall interior mirror assembly.

CAUTION:

Ensure that 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 5 hours, providing it is driven only on a smooth

road at speeds not exceeding 80 km/h.

3.2 MINOR WATER LEAK CORRECTION

1. Apply protective covering and masking tape

adjacent to the leak suspect area.

To determ ine the precise loc ation of the water leak ,

use the air/soap bubble leak test.

NOTE:

The soap/water solution can be applied with either

a spray applicator or brush.

2. Locate an air hose nozzle on the inside of the

windshield as illustrated in Fig. 1A6-20. Have

an assistant outside the vehicle apply a soapy

water solution opposite the air source. As a

medium air pressure (60kPa) is applied, soap

bubbles will form on the outside of the

windshield, indicating the location of the leak.

3. If the suspect leak area is not obvious,

commence the testing across the top and

down the sides until the leak loc ation has been

determined. Figure 1A6-23

4. Remove the windshield moulding (refer

preceding instructions) covering the leak

location then, if silicon is used, thoroughly dry

out the repair area with compressed air.

NOTE:

If urethane is being used, it is only necessary to

remove dust, foreign matter, etc. Water activates

the curing process of urethane.

5. Using a spatula, work fres h urethane or silicon

in and around the leak area.

6. If urethane has been used, leak test the repair,

using the air/soap bubble leak test or a non

pressurised water leak test.

IMPORTANT:

If silicon is used for spot sealing, allow a minimum

of one (1) hour to permit the silicon to skin and

adhere to the original urethane prior to testing the

repair.

Should the leak persist, apply additional

urethane/silicon until the leak has been corrected.

7. Reinstall any of the windshield moulding

removed to carry out the leak correction.

8. Clean windshield and adjacent paint finish,

then remove the masking tape and protective

covers.

Figure 1A6-24

3.3 REAR QUARTER WINDOW ASSEMBLY

STATION WAGON MODELS

REMOVE

1. Partially remove the door frame opening

moulding right and left side (refer to

Section 1A9 EXTERIOR ORNAMENTATION)

and release quarter window glass frame tab.

2. Remove ‘MOULDING ASSEMBLY, QUARTER

WINDOW INNER TRIM’, refer to

Section 1A8, HEADLINING AND REAR END

TRIM.

Figure 1A6-25

3. Remove the plastic nuts securing the window

to the body opening and carefully lift the glass

from the vehicle.

For sections A-A, and B-B refer to Fig. 1A6-27.

For sections C-C, and D-D refer to Fig. 1A6-28.

Figure 1A6-26

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REINSTALL

Reverse removal operations with following revision.

Leave quarter window retaining nuts loose until

door frame opening moulding is fastened in

position. Position quarter window and tighten

quarter window retaining nuts.

CAUTION:

Nuts to be tightened to 2 Nm.

Figure 1A6-27

Figure 1A6-28

3.4 TAILGATE WINDOW-STATION WAGON

WARNING:

Safety glasses and work gloves must be worn

at all times when operating with glass.

NOTE:

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 urethane at this temperature

and humidity takes 72 hours.

REMOVE

1. Disconnect battery ground cable.

2. Place protective covering around tailgate

opening.

3. Remove rear wiper blade and arm assembly,

refer to Section 12C, ‘INSTRUMENTS,

WIPERS, WASHERS & HORNS’.

4. Remove rear window washer nozzle, refer to

Section 1A4, REAR COMPARTMENT LID

AND TAILGATE.

5. Should the glass be broken, carefully remove

all fragm ents of glass f rom the tailgate window

aperture.

6. Remove glass following the procedure set out

in Steps 10 through 13, 3.1 WINDSHIELD

GLASS - REMOVE in this Section, carefully

cut out the tail gate window.

NOTE:

It is not necessary to remove all traces of original

urethane. However, any original urethane remaining

must be smooth and firm.

7. Remove ‘UPPER TRIM PANEL-TAILGATE,

and ‘LOWER TRIM PANEL-TAILGATE’, refer

to Section 1A4, REAR COMPARTMENT LID

AND TAILGA TE’.

8. Remove electrical demist connectors.

9. Remove three nuts and two screws securing

Tailgate Air Deflector, refer to Section 1A4,

‘REAR COMPARTMENT LID AND

TAILGATE’.Figure 1A6-29

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LONG METHOD INSTALLATION

1. Using one of the applicators in the

replacement kit, apply flange primer to any

section of the windshield opening flange that

has been cleaned back to bare m etal or to the

painted. Allow this primer to dry for 15

minutes.

DO NOT TOUCH PRIMED SURFACES

NOTE:

If the tailgate opening mouldings have been

removed, reinstall or replace.

2. Thoroughly clean the inner surface and edges

of the tailgate glass to which the urethane is to

be applied, using clean cloths and a suitable

oil free cleaning solvent. Figure 1A6-30

3. Apply clear glass primer around the perimeter

of the tailgate glass.

4. Reinstall the tailgate moulding over the edge

of the glass, with moulding joint at centre line

upper side of glass, ensure moulding is fitted

correctly to glass.

Figure 1A6-31

5. Using the applicator included in the

replacement kit, apply glass primer (black)

around the perimeter of the tailgate glass.

6. Using a hand or automatic applicator, apply a

smooth continuous bead of urethane

adhesive, such as Betaseal 554.02 or

equivalent, between the centre and outer

edge, on top of original urethane and around

entire perimeter of the body opening. The

urethane bead should be a minim um of 6 mm

in diameter.

NOTE:

Urethane service kits are available from most agent

around Australia. Manufacturer’s instructions

should always be followed.

NOTE:

In cold weather, the placement of cartridges

adjacent to a source of warmth will assist the flow

of urethane when using a hand applicator.

Figure 1A6-32

7. W ith the aid of an assistant, ins tall the tailgate

glass using the previously attached masking

tape on the tailgate to ensure accurate

installation. Press the glass firmly into position.

8. Check effectiveness of sealing from inside of

the vehicle. Should any gaps in the sealing

exist, apply additional urethane on the outside

to fill these gaps. Using a flat bladed tool,

sm ooth the surface of the ur ethane around the

edge on the outside of the tailgate to ensure

effective sealing.

9. Water test the tailgate, using a moderate

spray of water.

NOTE:

Do not direct a heavy stream of water onto freshly

applied urethane. If a leak is evident, apply

additional urethane to the leak area, using a flat

bladed tool to work urethane into source of leak.

IMPORTANT:

If silicon is used for spot sealing, allow a minimum

of one (1) hour to permit the silicon to skin and

adhere to the original urethane prior to water

testing the repair.

10. Clean off any excess urethane/silicon using

Prepsol or white spirit. Clean the tailgate, then

remove the masking tape previously installed.

CAUTION:

Ensure that 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 5 hours, providing it is driven only on a smooth

road at speeds not exceeding 80 km/h.

Figure 1A6-33

SHORT METHO D INSTALLATION

Refer 3.1 WINDSHIELD GLASS in this Section.

Note that the clear and black primers must follow

the entire perimeter of the tailgate glass

3.5 BACK WINDOW - SEDAN MODELS

REMOVE

1. Disconnect battery ground cable.

2. Place protective covering adjacent to back

window to protect trim and paint finish.

3. Remove the right and left side roof finisher

mouldings, refer to Section 1A9, EXTERIOR

ORNAMENTATION.

4. Remove ‘MOULDING ASSEMBLY, REAR

WINDOW INNER TRIM’, refer to

Section 1A8, HEADLINING AND REAR END

TRIM.

5. Disconnect back window electrical demist

connectors.

6. Remove back window glass following

procedure set out in Steps 10 through 13 in

3.1 WINDSHIELD GLASS-REMOVE, in this

Section, carefully cut out the back window

glass.

NOTE:

It is not necessary to remove all traces of original

urethane. However, any original urethane remaining

must be smooth and firm.

CAUTION:

When working with glass, the wearing of safety

glasses and work gloves is mandatory.

Opening Check

1. Thoroughly check the back window

opening flange for any irregularities before

installation of replacement window.

CAUTION:

Care should be tak en to ensure that glass does not

strike the back window opening. Chipped edges

can lead to subsequent breakage of glass.

2. Check and if necessary, re-form the body

flange to produce a uniform flange to glass

contour.

3. Correctly locate the glass in the opening, then

tape mark the outer top of glass and roof on

the right and left side. This procedure assists

the operators to align the glass in the correct

horizontal plane during final installation.

Techline

LONG METHOD INSTALLATION

1. Using one of the applicators in the

replacement kit, apply flange primer to any

section of the back window opening flange that

has been cleaned back to bare m etal or to the

painted. Allow this primer to dry for 15

minutes.

DO NOT TOUCH PRIMED SURFACES

2. Thoroughly clean the inner surface and edges

of the back window glass to which the

urethane is to be applied, using clean cloths

and a suitable oil free cleaning solvent.

Figure 1A6-34

3. Apply clear glass primer around the perimeter

of the back window glass.

4. Reinstall the back window upper and lower

mouldings over the edge of the glass, ensure

moulding is fitted correctly to glass.

5. Reinstall two roof to glass retaining m ouldings

part No. 92057763 to left and right hand side

of glass . Ensure that m ouldings are pos itioned

to alignment marks, and are fitted correctly to

edge of glass.

Figure 1A6-35

6. Using the applicator included in the

replacement kit, apply glass primer (black)

around the perimeter of the bac k window glass

bonding surface over a width of 7,0 along the

inside edge of back window mouldings.

7. Using a hand or automatic applicator, apply a

smooth continuous bead of urethane

adhesive, such as Betaseal 554.02 or

equivalent, between the centre and outer

edge, on top of original urethane and around

entire perimeter of the body opening. The

urethane bead should be a minim um of 6 mm

in diameter.

NOTE:

Urethane service kits are available from most

windshield agent around Australia. Manufacturer’s

instructions should always be followed.

NOTE:

In cold weather, the placement of cartridges

adjacent to a source of warmth will assist the flow

of urethane when using a hand applicator.

Figure 1A6-36

8. With the aid of an assistant, install the back

window glass. Press the glass firmly into

position.

NOTE:

Ensure glass is centralised in body opening left to

right by checking the gap between the glass

moulding and “C” pillar.

NOTE:

Install back window glass in back window opening

within five minutes after application of urethane

adhesive.

Figure 1A6-37

9. Engage roof finisher moulding assembly over

side moulding as shown in Figure 1A6-38 and

slide along until roof finisher moulding is in

position (refer Figure 1A6-39).

10. Re-engage roof finisher moulding assembly

clips along roof until roof finisher moulding

assembly sits flush against roof, refer

Section 1A9 ‘EXTERIOR

ORNAMENTATION’.

NOTE:

Front of roof finisher moulding must be installed

under windshield moulding cover.

IMPORTANT:

Roof finisher mouldings must be fitted within 10

minutes of installing glass.

Figure 1A6-38

NOTE:

Ensure that endcap of roof finisher moulding is

aligned with quarter panel to roof moulding.

12. Check effectiveness of sealing from inside of

the vehicle. Should any gaps in the sealing

exist, apply additional urethane on the outside

to fill these gaps. Using a flat bladed tool,

sm ooth the surface of the ur ethane around the

edge on the outside of the tailgate to ensure

effective sealing.

13. Water test using a moderate spray of water.

NOTE:

Do not direct a heavy stream of water onto freshly

applied urethane. If a leak is evident, apply

additional urethane to the leak area, using a flat

bladed tool to work urethane into source of leak.

IMPORTANT:

If silicon is used for spot sealing, allow a minimum

of one (1) hour to permit the silicon to skin and

adhere to the original urethane prior to water

testing the repair.

14. Clean off any excess urethane/silicon using

Prepsol or white spirit. Clean the body

opening, then remove the masking tape

previously installed.

CAUTION:

Ensure that door windows are partially lowered to

eliminate pressure build up which can be caused by

slamming doors. A curing time 24 hours is

recommended, although the vehicle may be driven

after 5 hours, provided it is driven only on a sm ooth

road at speeds not exceeding 80 km/h.

Figure 1A6-39

SHORT METHO D INSTALLATION

Refer 3.1 WINDSHIELD GLASS in this Section.

Note that the clear and black primers must follow

the entire perimeter of the back window glass.

4. TORQUE WRENCH SPECIFI CATIONS

Instrument Panel and Cap Cover Attachment Screws 1 - 3

Demist Nozzle Securing Screws 1 - 3

Quarter Window Retaining Nuts 2

Quarter Window Plastic Securing Nuts 1 - 3

Tailgate Air Deflector Securing Nuts and Screws 2 - 5

5. SPECIAL TOOLS

TOOL NO. REF IN TEXT TOOL DESCRIPTION COMMENTS

AU390 FABRICATED T HANDLE WINDSCREEN

REMOVAL TOOL AND PIANO WIRE

AU390-1 PIANO WIRE

J39032 STATIONARY GLASS REMOVAL TOOL