15/08/2023 10:17:33

Roof - Glass (Remove and Replace)

Correction Code 10205002

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Warning
Wear appropriate personal protective equipment (PPE) including cut-resistant gloves and safety glasses when performing this procedure.
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CAUTION
For Europe only: Only technicians who have been trained in working with diisocyanates and have completed all required certification courses are permitted to perform procedures using urethane and other products containing diisocyanates. Proper personal protective equipment (PPE) must be worn when working with products containing diisocyanates.

Removal

  1. Open all 4 windows.
  2. Fold down the 2nd row seats.
  3. Lower the headliner. See Headliner (Remove and Install) .
  4. Apply painter's tape to the body panels that are adjacent to the glass roof.
  5. Note the gap and flush between the fixed glass roof and windshield, liftgate glass, and roof side rails.
  6. Cut an appropriate length of square wire and insert the wire into the square wire cutting tool.
  7. Push the tool through the adhesive near the RH rear corner of the glass. Pull the wire through and remove the tool.
  8. Connect the T-handles to the wire.
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    Note
    The next step requires two technicians, one inside the vehicle and the other outside the vehicle.
  9. Cut out the glass roof.
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    CAUTION
    Do not damage the satellite radio antenna at the rear of the glass.
    Tip: Use a trim tool to guide the square wire over the antenna.
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    Note
    Cut through the rear datum pin (near the satellite radio antenna) with the square wire.
  10. Prepare a padded stand to place the glass roof onto after it is removed in a later step.
  11. Secure suction cups to each corner of the glass roof.
  12. With assistance, remove the glass roof from the vehicle and place it onto the padded stand.
  13. Remove the old glass roof rear datum pin from the liftgate shell.

Installation

  1. Replace any plugs or butyl patches that were damaged during glass removal.
  2. Inspect the satellite radio antenna. Replace the antenna if it was damaged during glass removal. See Antenna - Satellite Radio - Roof-Mounted (Remove and Replace) .
  3. Use the adhesive scraper to remove the excess adhesive from the vehicle body.
  4. Clean the remaining adhesive on the vehicle body with alcohol wipes. Allow the alcohol to dry fully before continuing to the next step.
  5. Secure suction cups to each corner of the new fixed glass roof.
  6. If installing an updated fixed glass roof (part number 1490219-00-A or 1497747-00-A, or newer), and roof rack mounts are not already installed, install roof rack mounts on the vehicle, Fixed Glass Roof Rack (Retrofit), and then return to this procedure.
  7. With assistance, position the fixed glass roof on the vehicle for a test fitment.
  8. Use a plastic trim tool to fully seat the fixed glass roof seal under the windshield seal.
  9. Check that all gaps are within acceptable limits. Gap to windshield: 4.5 mm +/- 2 mm.
  10. With assistance, remove the fixed glass roof and place it, upside down, on a padded stand.
  11. Clean all mating surfaces on the fixed glass roof with alcohol wipes.
  12. Apply primer to the vehicle body as directed by the adhesive manufacturer. Ensure that the primer fully covers any nicks or scratches in the paint. If the vehicle is equipped with roof rack mounts, the path of primer application will differ, as illustrated.
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    Warning
    Check the expiration date of the primer and adhesive before use.
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    Note
    Check the primer and adhesive packaging for the appropriate working times for each product. Prepare the necessary tools and work environment so that the glass can be installed within the specified working times.
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    Note
    This procedure requires approximately 2 tubes of adhesive.
    Figure 1. Primer path without roof rack anchor
    Figure 2. Primer path with roof rack anchor
  13. Inspect the replacement roof glass for a thick extruded urethane bead.
    • Older roof glass with a thick extruded urethane bead, go to step 19.
    • Newer roof glass without a thick extruded urethane bead, continue to the next step.
  14. Cut one caulking nozzle to 8mm wide and 13mm deep, and cut a second caulking nozzle to 12mm wide and 19mm deep.
  15. Prepare the caulking gun and urethane cartridge with the smaller cut nozzle.
  16. Apply the urethane to the front edge and front secondary bead of the roof glass.
  17. Install the larger cut nozzle onto the urethane cartridge, and then apply urethane to the side and rear edges and the rear secondary beads.
  18. Go to step 21.
  19. Load the adhesive into a caulking gun, and then cut the applicator tip in a triangular pattern: 8 mm wide, 14 mm tall.
  20. Apply the adhesive to the vehicle, following the same path of application as the primer.
  21. With assistance, position the new glass roof on the vehicle, but do not apply weight to it yet.
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    Note
    Align the datum pin with the hole in the liftgate.
  22. Use a plastic trim tool to fully seat the fixed glass roof seal under the windshield seal.
  23. Press the roof glass into position.
    Tip: Use sandbags to press the roof glass onto the vehicle.
  24. Adjust the new glass roof for proper gaps and flush:
    • Gap to windshield: 4.5 mm +/- 2.0 mm
    • Flush to windshield: 0.0 mm +1.0/-2.0 mm
    • Gap to body sides (vehicles with roof rack anchors): 7.0 mm +/- 2.0 mm
    • Gap to body sides (vehicles without roof rack anchors): N/A
    • Flush to body sides: 0.0 mm +2.5/-0.5 mm
    • Gap to liftgate glass: 7.0 mm +1.5/-0.0 mm
    • Flush to liftgate glass: 1.0 mm +1.0/-2.0 mm
  25. Clean off any excess adhesive that was extruded from the joint.
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    Warning
    Do not drive the vehicle until the adhesive manufacturer’s recommended minimum drive-away time has passed. Dow Betaseal Express has a drive-away time of 1 hour minimum in temperatures of 0˚F (-18˚C) or warmer. If necessary, leave the tape applying pressure to the glass on the vehicle and advise the customer that they can remove it after 24 hours. Additionally, advise the customer that they should avoid high driving speeds and speed bumps for the next 24 hours.
  26. Reinstall the headliner.