Roof Glass Replacement
NOTE:
  • Put on gloves to protect your hands.
  • Wear eye protection while cutting the glass adhesive with piano wire.
  • Use seat covers to avoid damaging the seat.
  • Use glass adhesive set P/N 08C73-X0230N.
  1. Remove these items:
  1. Remove the molding (A) from the upper edge of the roof glass (B). If necessary, cut the molding with a utility knife.
  1. If the old roof glass is to be reinstalled, make alignment marks across the glass and body with a grease pencil.
  1. Apply protective tape along the edge of the body. Using an awl, make a hole through the adhesive from inside the vehicle at the corner portion of the roof glass. Push a piece of piano wire through the hole, and wrap each end around a piece of wood.
  1. 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 roof glass (B) as possible to prevent damage to the body.
    Carefully cut through the adhesive (C) around the entire roof glass.
  1. Carefully remove the roof glass.
  1. With a knife, scrape the old adhesive smooth to a thickness of about 2 mm (0.08 in.) on the bonding surface around the entire roof 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 fasteners from the body.
  1. Clean the body bonding surface with a sponge dampened in alcohol. After cleaning, keep oil, grease and water from getting on the clean surface.
  1. If the old roof glass will be reinstalled, use a putty knife to scrape off all of the old adhesive, the fasteners and the clips. Clean the inside face and the edge of the roof glass with alcohol where new adhesive will be applied. Make sure the bonding surface is kept free of water, oil and grease.
Cutting portions
  1. Attach the fastener (A) with adhesive tape A, and clip (B) with adhesive tape B to the inside face of the roof glass (C) as shown:
    • Be sure the fastener line up with the alignment marks (D).
    • Be careful not to touch the roof glass where adhesive will be applied.
    Adhesive tape A:
    Thickness 0.6 mm (0.024 in.)
    Adhesive tape B:
    Thickness 0.4 mm (0.016 in.)
    Width 18 mm (0.71 in.)

  1. Attach the seal (E) with adhesive tape C on the clip. Be careful not to touch the roof glass where adhesive will be applied.
    Adhesive tape C:
    Thickness 0.16 mm (0.006 in.)

  1. Attach the molding (A) with adhesive tape (B, C) to the edge of the roof glass (D):
    • Be sure each corner of the molding lines up with the ones of the roof glass.
    • Be careful not to touch the roof glass where adhesive will be applied.
    Adhesive tape (B):
    Thickness 0.8 mm (0.03 in.)
    Width 5 mm (0.2 in.)
    Adhesive tape (C):
    Thickness 0.8 mm (0.03 in.)
    Width 10 mm (0.39 in.)

  1. Attach the spacer (E) with adhesive tape to the inside face of the roof glass. Be careful not to touch the roof glass where adhesive will be applied.
    Adhesive tape:
    Thickness 0.16 mm (0.006 in.)
    Width 6.0 mm (0.24 in.)

  1. Attach the fastener to the body as shown.
  1. Set the roof glass (A) in the opening, and center it. Make alignment marks (B) across the roof glass and body with a grease pencil at the four points shown:
    • Align the clips (C) on the roof glass with the hole in the opening flange.
    • Be careful not to touch the roof glass where adhesive will be applied.
  1. Remove the roof glass.
  1. With a sponge, apply a light coat of glass primer roof glass (A) along the edge of the molding (B), and spacer (C) as shown, then lightly wipe it off with gauze or cheesecloth:
    • Do not apply body primer to the roof glass, and do not get 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 roof glass properly, causing a leak after the roof glass is installed.
    • Keep water, dust, and abrasive materials away from the primed surfaces.
  1. With a sponge, carefully apply a light coat of body primer to any exposed paint or metal around the flange where new adhesive will be applied. Let the body primer dry for at least 10 minutes:
    • Do not apply body primer to any remaining original adhesive on the flange.
    • Be careful not to mix up the body and glass primer sponges.
    • Never touch the primed surfaces with your hands.
  1. Cut a ‘‘V'' in the end of the nozzle (A) on the adhesive cartridge as shown.
  1. Put the cartridge in a caulking gun, and run a bead of adhesive (A) around the edge of the roof glass (B) between the molding (C) and spacer (D) as shown. Apply the adhesive within 30 minutes after applying the glass primer. Make a slightly thicker bead at each corner.
  1. Use suction cups to hold the roof glass over the opening, align it with the alignment marks made in Step 15 , and set it down on the adhesive. Lightly push on the roof glass until its edges are fully seated on the adhesive all the way around.
    NOTE: Do not open or close any of the doors for about an hour until the adhesive is dry.
  1. Scrape or wipe the excess adhesive off with a putty knife or towel. To remove adhesive from a painted surface or the roof glass, wipe with a soft shop towel dampened with alcohol.
  1. After the adhesive has dried, spray water over the quarter glass and check for leaks. Mark the leaking areas, 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 driven slowly.
  1. Reinstall all remaining removed parts.
    NOTE: 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).