Quarter Glass Replacement (5D)

Quarter Glass Replacement

NOTE:

Put on gloves to protect your hands.
Wear eye protection when removing the glass with piano wire.
Use seat covers to avoid damaging any surfaces.
Use glass adhesive set P/N. 08C73-X0230N.

1.	Remove these items: Quarter pillar trim Rear pillar outer trim

2.	Remove the front seal (A) from the front edge of the quarter glass (B). If necessary, cut the rubber dam with a utility knife.

3.	Right quarter glass: Disconnect the glass antenna connectors (A).

4.	Apply protective tape to along the inside and outside edges of the body and along the edge of the headliner. Using an awl, make a hole through the adhesive from inside the vehicle. Push a piece of piano wire through the hole, and wrap each end around a piece of wood.

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

If the quarter glass is to be reinstalled, take care not to damage the molding (D).
If the molding is damaged, replace the quarter glass, molding, and clips (E) as an assembly.
If any of the clips are broken, the quarter glass can be reinstalled using butyl tape (refer to 10).

Cutting positions:

6.	Carefully remove the quarter glass.

With a putty knife, scrape the old adhesive smooth to a thickness of about 2 mm (0.08 in.) on the bonding surface around the entire quarter glass opening flange:

Do not scrape down to the painted surface of the body; damaged paint will interfere with proper bonding.
Remove the clips and fastener from the body.

8.	Clean the body bonding surface with a sponge damaged in alcohol. After cleaning, keep oil, grease, and water from getting on the surface.

Apply a light coat of primer (C-100, or equivalent), then aplly a double-sided adhesive tape (A) (3M 4215L, or equivalent) to the molding (B) as shown. Glue the fastener (C) with adhesive tape (3M 5312, or equivalent) to the inside face of the quarter glass (D):

Be sure the fastener lines up with the alignment marks (E).
Be careful not to touch the quarter glass where adhesive will be applied.
Do not peel the separators off the double-sided adhesive tape.

10.

If the old quarter glass is to be reinstalled (and either clip is broken off the molding), apply a light coat of primer (C-100, or equivalent), then aplly butyl tape (A) to the molding (B) as shown.

Be careful not to touch the quarter glass where adhesive will be applied.
Do not peel the separator off the butyl tape.

11.

Glue the front seal (A) to the molding (B) of the quarter glass (C) with adhesive tape (D) (3M 4212, or equivalent). Before installing the front seal, apply primer (3M N-200, or equivalent) to the molding and glass, then glue the front seal. Be sure the top of front seal contacts the lower edge of the molding.

12.

Glue the fastener (A) with adhesive tape (3M 5312, or equivalent) to the body. Be sure the fastener lines up with the alignment marks (B). If the old quarter glass is to be reinstalled (and either clip is broken off the molding), seal the body holes with pieces of urethane tape (C). Then set the quarter glass upright in the opening, and make alignment marks (D) across the quarter glass and body with a grease pencil at the four points shown. Be careful not to touch the quarter glass where adhesive will be applied.

13.	Remove the quarter glass.

14.

With a sponge, apply a light coat of glass primer to the inside face of the quarter glass (A) along the front seal (B) and molding (C) as shown, then lightly wipe it off with gauze or cheesecloth:

Do not apply body primer to the quarter glass, and do not get the body and glass primer sponges mixed up.
Never touch the primed surfaces with your hands. If you do the adhesive may not bond to the quarter glass properly, causing a leak after the quarter glass is installed.
Keep water, dust, and abrasive materials away from the primed surface.

15.

With a sponge, apply a light coat of body primer to the original adhesive remaining around the quarter glass opening flange. Let the body primer dry for at least 10 minutes:

Do not apply glass primer to the body, and be careful not to mix up the glass and body primer sponges.
Never touch the primed surfaces with your hands.
Mask off the dashboard before painting the flange.

16.	Before filling a cartridge, cut a ‘‘V'' in the end of the nozzle (A) as shown.

17.

Pack adhesive into the cartridge without air pockets to ensure continuous delivery. Put the cartridge in a caulking gun, and run a bead of adhesive (A) around the edge of the quarter glass (B) as shown:

After applying the adhesive, peel the separator off the butyl tape.
Apply the adhesive within 30 minutes after applying the glass primer. Make slightly thicker bead at each corner.

18.	Fold the edge of the adhesive backing from the double-sided adhesive tape stuck in 9. If old quarter glass is to be reinstalled, peel the adhesive backings from the butyl tapes.

19.

Use suction cups (A) to hold the quarter glass (B) over the opening, align the clips or the alignment marks (C) made in 12, and set it down on the adhesive. Lightly push on the quarter glass until its edges are fully seated on the adhesive all the way around. Do not open or close the doors until the adheasive is dry.

20.	Scrape or wipe the excess adhesive off with a putty knife or towel. To remove adhesive from a painted surface or the quarter glass, wipe with a soft shop towel damaged with alcohol.

21.	Let the adhesive dry for at least 1 hour.

22.	Carefully pull the adhesive backing away, and push the molding (A) against the rear pillar to stick the adhesive tape (B).

23.	Spray water over the quarter glass and check for leaks. Mark the leaking areas and let the quarter glass dry, then seal with sealant. Let the vehicle stand for at least 4 hours after quarter glass installation. If the vehicle has to be used within the first 4 hours, it must be deriven slowy.

24.	Reinstall all remaining removed parts. Advise the customer not to do the following things for 2 to 3 days: Slam the doors with all the windows rolled up. Twist the body excessively (such as when going in and out of driveways at an angle or driving over rough, uneven roads).