Upper Rear Window Replacement

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NOTE:

Wear eye protection while cutting the glass adhesive with a piano wire.
Put on gloves to protect your hands.
Use seat covers to avoid damaging any surfaces.
Do not damage the upper rear window defogger grid lines and terminals.

Remove these items:
- Tailgate upper trim (see step 4 in TRIM REMOVAL/INSTALLATION - TAILGATE AREA )
- Tailgate side trim (see step 3 in TRIM REMOVAL/INSTALLATION - TAILGATE AREA )
- Tailgate middle trim (see step 2 in TRIM REMOVAL/INSTALLATION - TAILGATE AREA )
- Tailgate spoiler trim (see TAILGATE SPOILER TRIM REPLACEMENT )
- Rear wiper motor (see REAR WINDOW WIPER MOTOR REPLACEMENT )
Remove the upper seal (A) from the edge of the upper rear window (B). If necessary, cut the upper seal with a utility knife.

Fig 1: Identifying Upper Seal From Edge Of Upper Rear Window
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Disconnect the upper rear window defogger connectors (A).

Fig 2: Identifying Upper Rear Window Defogger Connectors
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Remove the grommet (A), and disconnect the washer tube (B), the joint tubes (C, D) and the one way valve (E). Remove the washer nozzle nut (F), then remove the washer nozzle (G).

Fig 3: Grommet, Washer Tube And Joint Tubes With Torque Specifications
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Pull out the washer tube (A) from the washer tube clips (B) as shown.

Fig 4: Identifying Washer Tube And Washer Tube Clips
Courtesy of AMERICAN HONDA MOTOR CO., INC.
If the old upper rear window will be reinstalled, make alignment marks across the glass and the body with a grease pencil.
Apply protective tape along the inside and outside edges of the body. Make a hole with an awl through the adhesive from inside the vehicle at a corner of the upper rear window. 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 upper rear window (B) as possible to prevent damage to the body, and carefully cut through the adhesive (C) around the entire upper rear window.

Fig 5: Pulling Piano Wire Back And Forth In Sawing Motion
Courtesy of AMERICAN HONDA MOTOR CO., INC.

Cutting positions

Fig 6: Identifying Windshield Cutting Positions
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Carefully remove the upper rear window.
Scrape smooth the old adhesive with a knife until there is a thickness of about 2 mm (0.08 in) on the bonding surface around the entire upper rear window opening flange:
- Do not scrape down to the painted surface of the body; damaged paint will interfere with proper bonding.
- Remove the fasteners from the body.
Clean the body bonding surface with a shop towel dampened in isopropyl alcohol. After cleaning, keep oil, grease, and water from getting on the surface.
If you are installing the new upper rear window, install the rear wiper seal (A) to the upper rear window with its alignment mark (B) being aligned with the mark (C) on the upper rear window.

Fig 7: Identifying Rear Wiper Seal To Upper Rear Window
Courtesy of AMERICAN HONDA MOTOR CO., INC.
If you are reinstalling the old window, scrape off all of old adhesive, the fasteners, and the rubber dams from the upper rear window with a putty knife. Clean the bonding surfaces on the inside face and the edge of the upper rear window with isopropyl alcohol. Make sure the bonding surface is kept free of water, oil, and grease.
Apply glass primer to the edge of the upper rear window (A) where the new upper seal (B) will be attached as shown. Attach the upper seal with adhesive tape to the lower edge of the upper rear window:
- Be careful not to touch the window where the adhesive will be applied.
- After installing the upper seal, cut the ends (C) of the upper seal as shown.
  
  Fig 8: Applying Glass Primer To Edge Of Upper Rear Window
  Courtesy of AMERICAN HONDA MOTOR CO., INC.
Apply glass primer to the fasteners (A) mounting areas on the upper rear window (B), and let it dry. Attach the upper rubber dam (C), the side rubber dams (D), the lower rubber dam (E), and the fasteners with the adhesive tape to the inside face of the upper rear window as shown:
- Make sure the upper rubber dam, the side rubber dams, the lower rubber dams, and the fasteners line up with the alignment marks (F). If necessary, cut the excess rubber dams.
- Be careful not to touch the upper rear window where the adhesive will be applied.
  
  Fig 9: Identifying Fasteners Mounting Areas On Upper Rear Window
  Courtesy of AMERICAN HONDA MOTOR CO., INC.
Apply glass primer to the washer tube mounting areas on the upper rear window (A), and let it dry. Attach the washer tube clips (B), the washer joint (C) and the sponge tape (D) with adhesive tape to the upper rear window:
- Be careful not to touch the upper rear window where the adhesive will be applied.
- Make sure the washer tube clips, the washer joint, and the sponge tape with the alignment marks, (E).
  
  Fig 10: Applying Glass Primer To Washer Tube Mounting Areas
  Courtesy of AMERICAN HONDA MOTOR CO., INC.
Attach the fasteners (A, B) with the adhesive tape to the tailgate (C) as shown.

Fig 11: Attaching Fasteners With Adhesive Tape To Tailgate
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Set the upper rear window (A) in the opening, and center it. Make alignment marks (B) across the upper rear window and the body with a grease pencil at the four points shown. Make sure the pins (C) of both fasteners (D) contact with the edge of the body holes. Be careful not to touch the upper rear window where the adhesive will be applied.

Fig 12: Setting Upper Rear Window
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Remove the upper rear window.
Apply a light coat of glass primer to the upper rear window (A) along the edge of the rubber dams (B) as shown, then lightly wipe it off with gauze or cheesecloth:
- Apply the glass primer to the corner areas of the upper rear window using the printed dots (C) on the upper rear window as a guide.
- Do not apply body primer to the upper rear window, and do not mix up the body and the glass primer applicators.
- Never touch the primed surfaces with your hands. If you do, the adhesive may not bond to the upper rear window properly, causing a leak after the upper rear window is installed.
- Keep water, dust, and abrasive materials away from the primed surfaces.
  
  Fig 13: Applying Glass Primer To Corner Areas Of Upper Rear Window
  Courtesy of AMERICAN HONDA MOTOR CO., INC.
Carefully apply a light coat of body primer to any exposed paint or metal around the flange where the new adhesive will be applied. Let the body primer dry for at least 10 minutes:
- Do not apply body primer to any remaining old adhesive on the flange.
- Be careful not to mix up the body primer applicators and the glass primer applicators.
- Never touch the primed surfaces with your hands.
  
  Fig 14: Applying Body Primer To Any Exposed Paint
  Courtesy of AMERICAN HONDA MOTOR CO., INC.
Cut a "V" in the end of the nozzle (A) on the adhesive cartridge as shown.

Fig 15: Identifying "V" In End Of Nozzle On Adhesive Cartridge
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Put the cartridge in a caulking gun, and run a continuous bead of the adhesive (A) to the upper rear window (B) along the edge of the rubber dams (C) as shown:
- Use the printed dots (D) as a guide when you apply the adhesive to the corners of the upper rear window.
- Apply the adhesive within 30 minutes after applying the glass primer. Make a slightly thicker bead at each corner.
- Make a slightly thicker bead at each corner.
Hold the upper rear window with suction cups over the opening, align it with the alignment marks you made in step 18, and set it down on adhesive. Lightly push on the upper rear window until its edges are fully seated on adhesive all the way around.
NOTE: Do not open or close any of the doors for about an hour until adhesive is dry.
Remove the excess adhesive with a putty knife or a shop towel dampened in isopropyl alcohol.
Wait at least an hour for the adhesive to dry, then spray water over the upper rear window and check for leaks. Mark the leaking areas, let the upper rear, window dry, then seal with sealant. Let the vehicle stand for at least 4 hours after upper rear window installation. If the vehicle has to be used within the first 4 hours, it must be driven slowly.
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).