SECTION 1A6 - STATIONARY GLASS

IMPORTANT

Before performing any Service Operation or other procedure described in this Section, refer to

Section 00 CAUTIONS AND NOTES for correct workshop practices with regard to safety and/or

property damage.

1. GENERAL DESCRI PTI O N

Stationary glass on WH Series models is bonded to the body openings with the exception of the rear quarter

window, which is secured with plastic nuts.

The windshield, which is laminated and features a tinted upper band, is bonded in the body opening w ith urethane.

The rear window, w hich has an electrically heated demist facility, is also bonded in the body opening w ith urethane.

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

For replacement of urethane bonded glasses, urethane service kits have been developed and must be used to

ma intain original installation requirem ents. Glass ins talled with ur ethane requires either partial or complete removal of

the urethane when replacing the glass.

Two differ ent installation m ethods are us ed when replac ing the windshield or r ear window, a ‘short method’ and a ‘long

method’. Partial removal of the urethane 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 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 m aximum 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 body 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 body opening. In these cases, the

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

A one piece windshield moulding is now used in place of the two piece mould previously fitted to VT Series models.

For service procedures related to the rear door fixed window, refer to Section 1A5 FRONT & REAR DOOR

ASSEMBLIES in this Supplement.

Techline

2. SERVICE NOTES

CAUTION: Safety glasses and work gloves must be worn at all times when operating with glass.

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.

Urethane service kits are available from most windshield agents. Manufacturer’s instructions should always be

followed.

Window glass should be installed in the window opening within 5 minutes of the application of urethane.

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 m ust be taken during glass r emoval 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 the WH Series Parts information for

details.

CAUTION: Care must be taken during any

operation involving windshield removal or

installation not to exert any load on the

windshield glass. Failure to observe this may

result in damage to the glass.

1. To prevent damage to paint f inis h and trim, and

to minimise clean up, mask-up and place

protective covers over parts adjacent to the

windshield.

2. Prise cap (1) from wiper arm (2) and remove

wiper arm retaining nut (3) from drive spindle

(4).

T21A6001

Figure 1A6-1

Techline

3. Remove six scrivets (1) retaining both left

plenum cover (2) and right plenum cover (3).

Remove the plenum covers, taking care not to

break the retaining lugs (4).

T21A6002

Figure 1A6-2

4. Rem ove six sc rivets (1) retaining plenum water

deflector (2), pull deflector towards front of

vehicle, disengaging the four retaining tabs (3)

and remove from the vehicle.

T21A6003

Figure 1A6-3

5. Remove windshield moulding (1) by pulling the

moulding from the windshield to body join (2),

starting at the windshield lower corner (3) and

working around the windshield.

T21A6004

Figure 1A6-4

6. From inside vehicle, remove instrument panel

end cap cover right side and left side. Refer to

Section 1A3 INSTRUMENT PANEL AND

CONSOLE in this Supplement.

7. Remove retaining screws (1) from the outer

ends of the demist nozzles (2).

8. Carefully disengage the horizontal retaining

lugs (3) of both demist nozzles, from the top of

the instrument panel (4) with minimum upward

movement of the demist nozzles. This is to

ensure that minimal leverage is placed on the

outer vertical retaining lugs (5).

9. Disengage the vertical retaining lugs on the end

of the demist nozzles by pulling backward and

upward, until the demist nozzles are

disengaged from the instrument panel.

T21A6005

Figure 1A6-5

IMPORTANT: Note that on all vehicles a remote

receiver module, and on some models a solar

sensor, is installed between the left-hand and right-

hand demist nozzles on the instrum ent panel. Care

must be taken to avoid damage to the remote

receiver module (and solar sensor where fitted)

during windscreen removal procedure. It is not

necessary to remove the remote receiver module

(or solar sensor). Fig. 1A6-6 illustrates:

1. Remote receiver module / solar sensor.

2. Wiring harness connector.

3. Right-hand demist nozzle.

4. Left-hand demist nozzle.

5. Wiring harness.

T21A6006

Figure 1A6-6

10. Remove interior mirror assembly by sliding

mirror base upwards.

11. Remove A-pillar trim assembly, refer to

Section 1A8 HEADLINING AND REAR END

TRIM in this Supplement.

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

equivalent (refer to Fig. 1A6-7 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 1: Use at least 700 mm of wire between the

T-handles.

NOTE 2: Ensure that the headlining and other trim

items are not damaged.

T21A6007

100mm

10mm

100mm 2m m

Figure 1A6-7

13. 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 (1) 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

outside operator pulls the wire up to the interior T-

handle in a ‘walking’ motion refer to Figs. 1A6-8,

1A6-9, 1A6-10, and 1A6-11.

T21A6008

Figure 1A6-8

T21A6009

Figure 1A6-8

T21A6010

Figure 1A6-10

T21A6011

Figure 1A6-11

14. Carefully lift the windshield out of the body

opening. If there is evidence of glass adhering

to the urethane, cut the area again with the

piano wire.

15. If the original windshield is to be installed

again, 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.

LONG METHOD INSTALLATION

DESCRIPTION

The long method windshield 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.

PREPARATION

IMPORTANT: Note that on all vehicles a remote

receiver module, and on some models a solar

sensor, is installed between the left- hand and right-

hand demist nozzles on the instrum ent panel. T ak e

particular care during the urethane removal

procedure to avoid damage to the remote receiver

module (and solar sensor where fitted).

CAUTION: 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.

1. Using a sharp scraper, carefully remove any

original urethane from around the windshield.

Clean the windshield to be installed with a

suitable oil free cleaning agent.

2. Using a knife or sharp scraper, remove the

original urethane from around the entire

perimeter of the windshield opening flange.

Avoid the removal of paint when removing

urethane from opening flange.

Body Opening Check

1. Thoroughly check the windshield body opening

flange fo r any irregularities before installing the

windshield.

2. Remove the A-pillar trims. Refer to Section

1A8 HEADLINING AND REAR END TRIM in

this SupplementSupplement.

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. Place the windshield in the body opening

temporarily to check for correct alignment

between the windshield and body opening. If

necessary, reform the body opening flange to

produce a uniform flange to windshield contour.

4. Using a wedge (1) placed between the lower

edge of the windshield (2) and the reinforcing

flanges (3), correctly locate the windshield in

the body opening.

5. Tape mark the outer top and side of the

windshield, pillar and roof with masking tape

(4). 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

T21A6012

...

.....

........

.....

....

...

Figure 1A6-12

REINSTALL

1. Using one of the applicators in the service kit,

apply flange primer (1) to any section of the

windshield opening flange that has been

cleaned back to bare metal or to be painted.

Allow this primer to dry for 15 minutes.

IMPORTANT: Do not touch primed surfaces.

2. Thoroughly clean the inner surface and edges

of the windshield to which the urethane is to be

applied, using clean lint-free cloths and a

suitable oil free cleaning solvent.

T21A6013

-A

Figure 1A6-13

3. Apply clear glass primer to inner surface of

glass around the perimeter of the windshield

over the width of the solid black ceramic

pattern (or a width of 50 mm) and immediately

wipe off with a lint-free cloth.

4. Check the condition of the windshield

moulding. Discard and replace with new

moulding if damaged.

50mm

T21A6014

Figure 1A6-14

5. Fit windshield moulding (1) to sides and upper

section of windshield. Ensure that notch of

moulding (2) is aligned with ‘V’ locating mark

(3) on lower portion of right-hand and left-hand

side of windshield.

T21A6015

Figure 1A6-15

6. Using the applicator (1) included in the service

kit, apply black glass primer (2) to the

windshield (3) alongside the moulding (4).

T21A6016

Figure 1A6-16

7. Apply black glass primer (1) to the inner

surface of the upper section (2) and sides (3) of

the windshield over a width of 20 mm inboard

from the moulding (4). Repeat this process

35 mm from the lower edge (5) of the

windshield. Ensure that a suitably reduced

application of primer black glass primer (6) is

applied 15 mm from the lower edge of the

windshield (7) adjacent to the VIN plate (8).

T21A6017

A-A

20mm

BBB

B-B

20mm

C-C

20mm

35mm

D-D

15mm

Figure 1A6-17

8. Using a hand or automatic applicator, apply a

smooth continuous bead of urethane (1), such

as Betaseal 587.02 or equivalent, to the

windshield (2) alongside the moulding (3).

T21A6018

Figure 1A6-18

IMPORTANT: On the lower left-hand side 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.

9. Apply urethane ( 1) adjac ent to the m oulding ( 2)

and 35 mm inboard (3) from the lower edge of

the windshield (4). A suitably reduced amount

of urethane (5) should be applied adjacent to

the VIN plate (6) to ensure that the VIN is not

obscured when the windshield is installed. All

other bead dimensions are shown in Fig. 1A6-

19.

T21A6019

BBB

D-D

15mm

B-B

14 mm

–0

7 mm

–0

C-C

35mm

14 mm

–0

7 mm

–0

A-A

14 mm

–0

7 mm

–0

Figure 1A6-19

NOTE: In cold weather, the plac ement of c ar tridges

adjacent to a source of warmth will assist the flow

of urethane when using a hand applicator.

10. Install the interior mirror assembly.

IMPORTANT: For ease of installation and to avoid

unnecessary stress on related components, it is

recommended that the interior mirror assembly be

fitted to the windshield prior to installation of the

windshield to the vehicle.

11. With the aid of an assistant, install the

windshield, using the previously attached

masking tape (1) on the roof and windshield to

ensure accurate installation. Use a wedge (2)

placed between the lower windshield edge (3)

and the reinforcing flanges (4) to locate glass

vertically in the windshield opening. Press

windshield firmly into position.

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 spatula, smooth the

surf ace of the urethane around the edge on the

outside of the windshield to ensure effective

sealing.

13. Water test the windshield, using a moderate

spray of water.

T21A6020

...

.....

........

.....

....

...

Figure 1A6-20

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

spatula to work urethane into source of leak.

IMPORTANT: If silicon is used for spot sealing,

allow a minimum of 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 windshield,

then remove the masking tape previously

installed.

15. Install the A-pillar trims. Refer to Section 1A8

HEADLINING AND REAR END TRIM in this

Supplement.

16. Install the dem ist nozzles and retaining screws.

Install the instrument panel end cap covers.

Refer to Section 1A3 INSTRUMENT PANEL

AND CONSOLE in this Supplement.

17. Install the plenum chamber water deflector,

right-hand and left-hand side plenum covers

and wiper arm assemblies.

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, prov iding it is driven only on a smooth

road at speeds not exceeding 80 km/h with the

door windows partially lowered.

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 urethane 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.

PREPARATION

CAUTION: Care should be taken to ensure that

glass does not strike the windshield opening.

Chipped edges can lead to subsequent

breakage of glass.

1. Using a wedge (1) placed between the lower

edge of the windshield (2) and the reinforcing

flanges (3), correctly locate the windshield in

the body opening.

2. Tape mark the outer top and side of the

windshield, pillar and roof with masking tape

(4). This procedure will assist in the alignment

of the windshield in the correct horizontal and

vertical plane during final windshield

installation.

3. Remove and place the windshield face down

on a clean protected surface or fixture.

T21A6012

...

.....

........

.....

....

...

Figure 1A6-21

REINSTALL

1. Thoroughly clean the inner surface and edges

of the windshield to which the urethane is to be

applied, using clean lint-free cloths and a

suitable oil free cleaning solvent.

2. Apply clear glass primer to inner surface of

glass around the perimeter of the windshield

over the width of the solid black ceramic

pattern (or a width of 50 mm) and immediately

wipe off with a lint-free cloth.

3. Check the condition of the windshield

moulding. Discard and replace with new

moulding if damaged.

50mm

T21A6014

Figure 1A6-22

4. Fit windshield moulding (1) to sides and upper

section of windshield. Ensure that notch of

moulding (2) is aligned with ‘V’ locating mark

(3) on lower portion of right-hand and left-hand

side of windshield.

T21A6015

Figure 1A6-23

5. Check the original urethane around the

windshield opening flange for voids or

looseness. Cut away any loose pieces of

urethane and, using a suitable spatula, paddle

fresh urethane or silicon smoothly into any

voids or uneven sections.

6. Using the applicator (1) included in the service

kit, apply black glass primer (2) to the

windshield (3) alongside the moulding (4).

T21A6016

Figure 1A6-24

7. Apply black glass primer (1) to the inner

surface of the upper section (2) and sides (3) of

the windshield over a width of 20 mm inboard

from the moulding (4). Repeat this process

35 mm from the lower edge (5) of the

windshield. Ensure that a suitably reduced

application of primer black glass (6) is applied

15 mm from the lower edge of the windshield

(7) adjacent to the VIN plate (8).

T21A6017

A-A

20mm

BBB

B-B

20mm

C-C

20mm

35mm

D-D

15mm

Figure 1A6-25

8. Using a hand or automatic applicator, apply a

smooth continuous bead of urethane (1), such

as Betaseal 587.02 or equivalent, to the

windshield (2) alongside the moulding (3).

T21A6018

Figure 1A6-26

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.

9. Apply urethane ( 1) adjac ent to the m oulding ( 2)

and 35 mm inboard (3) from the lower edge of

the windshield (4). A suitably reduced amount

of urethane (5) should be applied adjacent to

the VIN plate (6) to ensure that the VIN is not

obscured when the windshield is installed. All

other bead dimensions are shown in Fig. 1A6-

27.

T21A6019

BBB

D-D

15mm

B-B

14 mm

–0

7 mm

–0

C-C

35mm

14 mm

–0

7 mm

–0

A-A

14 mm

–0

7 mm

–0

Figure 1A6-27

NOTE: In cold weather, the plac ement of c ar tridges

adjacent to a source of warmth will assist the flow

of urethane when using a hand applicator.

10. Install the interior mirror assembly.

IMPORTANT: For ease of installation and to avoid

unnecessary stress on related components, it is

recommended that the interior mirror assembly be

fitted to the windshield prior to installation of the

windshield to the vehicle.

11. With the aid of an assistant, install the

windshield, using the previously attached

masking tape (1) on the roof and windshield to

ensure accurate installation. Use a wedge (2)

placed between the lower windshield edge (3)

and the reinforcing flange (4) to locate glass

vertically in the windshield opening. Press

windshield firmly into position.

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 spatula, smooth the

surf ace of the urethane around the edge on the

outside of the windshield to ensure effective

sealing.

13. 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

spatula to work urethane into source of leak.

T21A6020

...

.....

........

.....

....

...

Figure 1A6-28

IMPORTANT: If silicon is used for spot sealing,

allow a minimum of 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 windshield,

then remove the masking tape previously

installed.

15. Install the A-pillar trims. Refer to Section 1A8

HEADLINING AND REAR END TRIM in this

Supplement.

16. Install the dem ist nozzles and retaining screws.

Install the instrument panel end cap covers.

Refer to Section 1A3 INSTRUMENT PANEL

in this Supplement.

17. Install the plenum chamber water deflector,

right-hand and left-hand side plenum covers

and wiper arm assemblies.

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, prov iding it is driven only on a smooth

road at speeds not exceeding 80 km/h with the

door windows partially lowered.

3.2 BACK WINDOW

REMOVE

CAUTION: Safety glasses and work gloves

must be worn at all times when operating with

glass.

1. Disconnect battery ground cable.

2. Place protective covering adjacent to back

window to protect trim and paint finish.

3. Remove the rear window inner trim moulding

assembly, refer to Section 1A8 HEADLINING

AND REAR END TRIM in this Supplement.

4. Carefully disconnect the back window electr ical

demister connectors and cellular telephone

antenna if fitted.

5. Should the glass be broken, carefully remove

all fragments of glass from the back window

opening. Otherwise, carefully cut out the back

window glass by following the procedure set

out in Steps 12 to 15 of 3.1 WINDSHIELD

GLASS in this Section.

NOTE: It is not necessary to remove all traces of

the original urethane. However, any original

urethane remaining must be smooth and firm.

Body Opening Check

1. Thoroughly check the back window opening

flange fo r any irregularities before installation of

replacement window.

CAUTION: Care should be taken 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 body opening,

then tape mark the outer top of glass and roof

on the right-hand and left-hand sides. This

procedure will assist the alignm ent of the glass

in the correct horizontal plane during final

installation.

LONG METHOD INSTALLATION

1. Using one of the applicators in the service kit,

apply flange primer (1) to any section of the

back window opening flange that has been

cleaned back to bare metal or to be painted.

Allow this primer to dry for 15 minutes.

IMPORTANT: Do not touch primed surfaces.

2. Thoroughly clean the inner surface and edges

of the back window glass to which the ur ethane

is to be applied, using clean lint- free cloths and

a suitable oil free cleaning solvent.

WH1A632

-A

Figure 1A6-29

3. Apply clear glass prim er to the inner surface of

glass around the perimeter of the back window

edge over the width of the black ceramic and

immediately wipe off with a lint-free cloth.

WH1A633

Figure 1A6-30

4. Check the condition of the back window

moulding and replace if damaged. Install the

moulding (1) over the edge of the glass,

ensuring that the moulding is fitted correctly

with its butt-welded joint (2) centrally located at

the base of the glass. Refer to Fig. 1A6-31.

5. Using the applicator (3) included in the service

kit, apply black glass primer (4) around the

perimeter of the back window glass bonding

surf ace over a width of 20 mm along the inside

edge of back window moulding.

6. Using a hand or automatic applicator, apply a

smooth continuous bead of urethane (5), such

as Betaseal 587.02 or equivalent, inboard of

the mouldings around the entire perimeter of

the body opening. The urethane bead should

be as specified in Fig. 1A6-31.

NOTE: In cold weather, the placement of c artr idges

adjacent to a source of warmth will assist the flow

of urethane when using a hand applicator.

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

window glass and press the glass firmly into

position.

NOTE: Ensure glas s is centr alised in body opening

left to right by checking that the gaps between the

glass m oulding and C-pillar are even on both sides

of the vehicle.

WH1A634

A-A

B-B

C-C

20mm

7 mm

–0

7 mm

–0

14 mm

–0

14 mm

–0

14 mm

–0

7 mm

–0

A B

Figure 1A6-31

1. Moulding 3. Applicator 5. Urethane

2. Butt-weld joint (on Centre line) 4. Black glass primer

8. If rem oved or partially removed, ensur e that the

roof f inisher m oulding assembly is installed into

the channel of the roof panel as shown in

Fig. 1A6-32. Engage roof finisher moulding

assembly clips along roof until roof finisher

moulding assembly sits flush against roof as

shown in Section A-A. Refer to Fig. 1A6-32.

The following items are illustrated.

1. Roof finisher moulding.

2. Roof finisher moulding locating c lips (s even

places, ensure lead clip is installed under

roof panel flange).

3. Roof panel.

NOTE: Front of roof finisher moulding must be

installed under windshield moulding.

Figure 1A6-32

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 spatula, smooth the

surf ace of the urethane around the edge on the

outside of the back window to ensure effective

sealing.

10. 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

spatula to work urethane into source of leak.

IMPORTANT: If silicon is used for spot sealing,

allow a minimum of 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, then remove the

masking tape previously installed.

12. Connect the electrical demist connectors, and

cellular telephone antenna if fitted, (refer

Section 12G CELLULAR MOBILE PHONE of

this Service Information CD) then clean the

rear window and surrounding area.

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, pr ovided it is driven only on

a smooth road at speeds not exceeding 80 km/h.

SHORT METHOD INSTALLATION

The short method of installation for the back

window is the same as that detailed in

3.1 WINDSHIELD GLASS in this Sec tion. Note that

the clear and black primers must follow the entire

perimeter of the back window glass.

3.3 REAR QUARTER WINDOW

REMOVE

1. Partially remove the front pillar drip moulding.

Refer to Section 1A9 EXTERIOR

ORNAMENTATION in this Supplement.

2. Remove the rear quarter window inner trim.

Refer to Section1A8 HEADLINING AND

REAR END TRIM in this Supplement.

3. Remove the five plastic nuts securing the

window to the body opening and carefully lift

the glass from the vehicle.

REINSTALL

Reverse removal operations.

NOTE: Should the foam weatherstrip, which seals

the window to the body opening, require

replacement, sections are available. Refer to WH

Series parts information for details.

Figure 1A6-33

Tab to engage with doorframe opening moulding

right and left-hand.

1. Nut (5 places).

2. Sixth window assembly.

3. Apply sealer to butt joint in foam seal.

4. Foam seal.

Sections show installed condition.

Techline

3.4 MINOR WATER LEAK CORRECTION

1. Secure protective covering with masking tape

adjacent to the leak suspect area.

NOTE: To determine the precise location of the

water leak, use the air/soap bubble leak test. The

soap/water solution can be applied with either a

spray applicator or brush as illustrated in Fig. 1A6-

34.

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

windshield as illustrated in Fig. 1A6-35. Have

an assistant outside the vehicle apply a soapy

water solution opposite the air s ource. As a low

air pressure (60 kPa) 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,

com mence the tes ting ac ros s the top and down

the sides until the leak location has been

determined.

T21A6033

Figure 1A6-34

4. It may be necessary to lift or rem ove moulding

covering the leak location.

NOTE 1: If silicon is to be used, thoroughly dry out

the repair area with compressed air.

NOTE 2: If urethane is to be used, it is only

necessary to remove dust, foreign matter, etc.

Water activates the curing process of urethane.

5. Using a spatula, work fresh 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 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. Secure the section of moulding lifted or

removed to carry out the leak correction.

8. Remove the masking tape and protective

covers, then clean the glass and adjacent paint

and trim surfaces.

T21A6034

Figure 1A6-35

4. TORQUE WRENCH SPECIFI CATIONS

Instrument Panel and Cap Cover Attachment Screws ......... 1 - 3

Demist Nozzle Securing Screws........................................... 1 - 3

Quarter Window Plastic Securing Nuts................................. 1 - 3

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