Subaru BRZ 2013 · Service Manual Exterior body & electrical

Back window glass

Components Removal / installation

GLASS & WINDOW

BACK WINDOW GLASS

EXPLODED VIEW

REMOVAL

1. Removal of separate type rear seat cushion ASSY LH (Refer to

)

2. Removal of separate type rear seat cushion ASSY RH

NOTE:

Perform operation following the same procedure as LH side.

3. Removal of the front door scuff plate RH (Refer to

)

4. Removal of front door scuff plate LH

NOTE:

Perform the same procedures as RH side.

5. Removal of front door opening trim weather strip RH (Refer to

)

6. Removal of front door opening trim weather strip LH

NOTE:

Perform the same procedures as RH side.

7. Removal of the trunk trim cover INN RH (Refer to

)

8. Removal of the trunk trim cover INN LH

NOTE:

Perform the same procedures as RH side.

9. Removal of quarter lower trim RH (Refer to

)

10. Removal of quarter lower trim LH

NOTE:

Perform the same procedures as RH side.

11. Removal of quarter trim lid RH (Refer to

)

12. Removal of quarter trim lid LH

NOTE:

Perform the same procedures as RH side.

13. Removal of the rear window side garnish RH (Refer to

)

14. Removal of the rear window side garnish LH

NOTE:

Perform the same procedures as RH side.

15. Removal of package tray trim panel ASSY (Refer to

)

16. Removal of back window glass

CAUTION:

·The back window glass stopper is installed on the back window glass. Be careful not to damage the back window glass.
·Work with the windshield knife or piano wire according to cut location and/or condition.
·Use the suction rubber to keep back window glass in place from outside to avoid dropping the back window glass during operation.

(1) Apply protective tape to the body side of the circumference of back window glass.

Captions in illustration

*1	Protective tape

(2) Using the cutter knife, cut the back window outside molding UPR No. 1.

·Do not damage the back window glass and the body surface.
·If the body surface is damaged, remove the back window glass, and then perform the rust prevention treatment.

Captions in illustration

*1	Body
*2	Molding
*3	Back window glass
*a	Cut

(3) Pull the back window outside molding UPR No. 1 by hand to detach.

(4) When the back window glass is reused.

(a) Attach gummed tapes or similar tapes on the back window glass and body panel, and put alignment marks on them with a pen for reinstallation.

Captions in illustration

*a	Alignment marks

(5) Disconnect the defogger connector.

(6) Attach the suction rubber onto the back window glass.

(7) When using the windshield knife

(a) Apply sufficient amount of soapy water to the adhesive section.

(b) Insert the windshield knife into the adhesive section.

(c) Using the windshield knife, insert the blade between the back window glass and the vehicle body, and move the knife along the edge of the glass to cut adhesive while keeping the blade at right angle with the edge.

·Never twist the windshield glass knife.
·Do not damage the back window glass.

Begin from where the back window glass and the body is most distant.

Captions in illustration

*1	Back window glass stopper
*2	Windshield knife
*3	Protective tape
*a	Align with the glass

(8) When using piano wire

(a) Using an air drill, make a hole in the adhesive section and pass the piano wire through the hole.

(b) Pass the piano wire (0.6 mm {0.024 in} is recommended) through the point shown in the figure, attach both ends of the wire to wooden boards.

(c) Pull the piano wire both ways and cut the adhesive on the back window glass.

·Do not tightly contact the piano wire against the back window glass edge.
·When working around the air bag, do not damage it with the piano wire.
·Make sure do not cross the piano wires. Otherwise, they can be cut.

Captions in illustration

*1	Back window glass stopper
*2	Piano wire

(9) Hold the suction rubbers, release the 2 tabs of the back window glass stopper, then remove the back window glass.

·The back window glass stopper is installed in the position shown on the back window glass figure. Be careful not to damage the back window glass.
·Work with the windshield knife or piano wire according to cut location and/or condition.
·Use the suction rubber to keep back window glass in place from outside to avoid dropping the back window glass during operation.

Captions in illustration

*1	Back window glass stopper

17. Removal of back window glass adhesive dam

(1) When the back window glass is reused.

(a) Using the scraper, remove the back window glass adhesive dam.

·Do not damage the back window glass.
·The back window glass dam kit must be replaced by a new one.

Captions in illustration

*1	Back window glass adhesive dam
*a	Backside of the back window glass

18. Removal of back window outside molding UPR No. 1

(1) When the back window glass is reused.

(a) Using the scraper, remove the back window outside molding UPR No. 1.

·Do not damage the back window glass.
·The back window outside molding UPR No. 1 must be replaced by a new one.

Captions in illustration

*1	Back window outside molding UPR No. 1
*a	Backside of the back window glass

1. Cleaning of back window glass

(1) When the back window glass is reused.

(a) Using a scraper or similar tool, remove the adhesive and/or back window glass adhesive dam remaining on the back window glass.

Do not damage the back window glass.

(2) Using the appropriate cleaner, clean the rim of the back window glass.

New back window glass also requires to be cleaned.

(3) Apply primer to mounting surface on the back window glass for the back window outside molding UPR No 1.

Primer : 3M N-200, Sunstar #GP402, or equivalent

Do not apply the primer thickly.

(4) Fit the back window outside molding UPR No. 1 to the both sides of the back window glass.

(5) Using a roller, crimp the back window outside molding UPR NO.1 in the direction specified by the arrows in the figure.

·Be careful to attach the back window outside molding UPR NO.1 firmly so that there is no loose part.
·Attach the back window outside molding UPR NO.1 after the primer dried (approx. 10 minutes).

Captions in illustration

*a	Backside of the back window glass

(6) Using a roller, crimp the back window outside molding UPR NO.1 in the direction specified by the arrows in the figure.

·Be careful to attach the back window outside molding UPR NO.1 firmly so that there is no loose part.
·Attach the back window outside molding UPR NO.1 after the primer dried (approx. 10 minutes).

Captions in illustration

*a	Backside of the back window glass

2. Installation of back window glass adhesive dam

(1) Using the appropriate cleaner, clean the installation surface of the back window glass adhesive dam.

(2) Attach new back window glass adhesive dam onto the place of backside of the back window glass where indicated in the figure.

Captions in illustration

*1	Back window glass adhesive dam	*2	Ceramic cutout
*a	Backside of the back window glass	-	-

Part	Dimension
a	3.0 mm {0.118 in} or less
b	19.9 to 21.9 mm {0.783 to 0.862 in}
c	18.9 to 20.9 mm {0.744 to 0.823 in}
d	6.0 to 8.0 mm {0.236 to 0.315 in}

3. Installation of back window glass

(1) Cleaning of mounting surface of the body

(a) Remove the adhesive layer on the body using cutter knife or similar tool to obtain smooth surface of 2 mm {0.08 in} thick.

·Do not damage the body.
·Always leave a little amount of adhesive.

Captions in illustration

*1	Body	-	-
	Adhesive	-	-

Part	Dimension
a	2.0 mm {0.079in}

(b) Using the appropriate cleaner, clean the body installation surface.

(2) Preliminary operation for back window glass installation

(a) Attach the suction rubber onto the back window glass.

(b) Temporarily place the back window glass on the body, and set it so that the upper and side sections for the back window glass become equal in width (consistent clearance between body and back window glass edge).

(c) Attach packing tapes or similar tapes on the back window glass and body panel, and put alignment marks on them with a pen for reinstallation. (When new back window glass is used.)

From inside the vehicle, check that the back window glass stoppers and the body are engaged.

When back window glass will be reused, check and correct the position of the alignment marks.

Captions in illustration

*a	Alignment marks

(d) Detach the back window glass.

(e) Apply primer on the body surface.

Primer : The Dow Automotive Betaprime 5402 or equivalent

·Do not apply the primer thickly.

(f) Apply primer onto backside of the back window glass, where indicated in the figure.

Primer : The Dow Automotive Betawipe VP 04604, Betaprime 5001, or equivalent

·Do not apply the primer thickly.

Captions in illustration

*1	Back window glass adhesive dam	*2	Primer
*a	Backside of the back window glass	-	-

Part	Dimension
a	8.0 mm {0.315in}

(g) Cut the tip of the adhesive nozzle, as shown in the figure.

Part	Dimension
a	2.0 mm {0.079in}
b	8.0 mm {0.315in}
c	9.0 mm {0.354in}

(h) Set the adhesive into the sealant gun.

Adhesive : The Dow Automotive Gurit-ESSEX Betaseal 1502 or equivalent

(i) Apply a bead of adhesive as shown in the figure.

Captions in illustration

*1	Back window glass adhesive dam	*2	Adhesive
*a	Backside of the back window glass	*b	Extra adhesive area

Part	Dimension
a	2.0 mm {0.079in}
b	8.0 mm {0.315in}
c	9.0 mm {0.354in}
d	9.8 mm {0.386in}
e	11.1 mm {0.437in}
f	2.5 mm {0.098in}

Apply adhesive after the primer dried (approx. after 10 minutes).

(3) Installation of back window glass

(a) Using the suction rubbers, position the alignment marks and install the back window glass.

Captions in illustration

*a	Alignment marks

From inside the vehicle, check that the back window glass stoppers and the body are engaged.

(b) Lightly press the front side of the back window glass to fit completely.

Pressing force: 98 N {10 kgf} {22.0 lbf} or more

(c) Using a spatula, remove or add adhesive if any excess and/or shortage is found.

(d) Remove excess adhesive before cure.

(e) Using protection tapes or similar tapes, hold the back window glass until the adhesive cures completely.

For minimum drying time or waiting time after the cure of adhesive, consult the instruction or manual of each adhesive supplier.

(4) Connect the defogger connector.

4. Leak test and repair

(1) After the adhesive cure, pour water over the back window glass from outside of the vehicle and make sure no water leak inside.

(2) If any water leak is found, fill the three cement black after the drying.

(3) Remove the applied protective tape and packing tape.

5. Installation of package tray trim panel ASSY (Refer to

)

6. Installation of the rear window side garnish RH (Refer to

)

7. Installation of rear window side garnish LH

NOTE:

Perform the same procedures as RH side.

8. Installation of the quarter trim lid RH (Refer to

)

9. Installation of quarter trim lid LH

NOTE:

Perform the same procedures as RH side.

10. Installation of the quarter lower trim RH (Refer to

)

11. Installation of quarter lower trim LH

NOTE:

Perform the same procedures as RH side.

12. Installation of trunk trim cover INN RH (Refer to

)

13. Installation of the trunk trim cover INN LH

NOTE:

Perform the same procedures as RH side.

14. Installation of the front door opening trim weather strip LH (Refer to

)

15. Installation of front door opening trim weather strip RH

NOTE:

Perform operation following the same procedure as LH side.

16. Installation of the front door scuff plate RH (Refer to

)

17. Installation of front door scuff plate LH

NOTE:

Perform the same procedures as RH side.

18. Installation of separate type rear seat cushion ASSY LH (Refer to

)

19. Installation of separate type rear seat cushion ASSY RH

NOTE:

Perform operation following the same procedure as LH side.