LEMON Manuals: Even more car manuals for everyone
Home >> Mazda >> 2004 >> 3 i, Automatic >> Repair and Diagnosis >> Body & Frame >> Windows >> Glass/Windows/Mirrors >> Rear Window Glass Installation >> 5 Door

5 Door

CAUTION:
  • Proper installation of the rear window glass may be difficult If sealant is cracked or the glass is pushed out by air pressure when a door is opened/closed with all the window glass closed. Leave all the windows open until the rear window glass is installed completely.
  1. Cut away the old sealant using a razor so that a 1-2 mm {0.04-0.07 in}  thickness of sealant remains along the perimeter of the frame.
    WARNING:
    • Using a razor with bare hands can cause injury. Always wear gloves when using a razor.
  2. If the sealant has come off completely in any one place, apply some primer after degreasing, and allow it to dry for approx. 30 min.  Then apply a 2 mm {0.08 in} thickness of sealant. 
  3. Clean and degrease the perimeter approx. 50 mm {1.97 in}  from the glass end and the bonding area on the body.
    Fig 1: Cutting Old Sealant Using Razor
    G02566754Courtesy of MAZDA MOTORS CORP.
  4. Install the dam along the perimeter of the glass.
    Fig 2: Locating Dam Installation Area
    G02566755Courtesy of MAZDA MOTORS CORP.
  5. Attach the fasteners and spacer to the area shown in the figure.
  6. Attach the pins to the seating positions where marked during removal.
  7. Apply glass primer on the rear window glass, and body primer on the rear window glass molding as shown in the figure. Allow it to dry for approx. 30 min. 
    CAUTION:
    • Keep the area free of dirt and grease, and do not touch the surface. Otherwise, the primer may not properly bond to the surface of the glass and body, which may cause leakage.
      Fig 3: Possible Primer Application Area
      G02566756Courtesy of MAZDA MOTORS CORP.
  8. Apply sealant to the glass surface as shown in the figure.
  9. Insert the positioning pins into the body, then install the rear window.
    Fig 4: Applying Sealant To Glass Surface
    G02566757Courtesy of MAZDA MOTORS CORP.
  10. Press the rear window pins to engage the tabs to the body.
    Fig 5: Pressing Rear Window Pins To Engage Tabs To Body
    G02566758Courtesy of MAZDA MOTORS CORP.
  11. Press completely along the perimeter of the glass.
  12. Connect the filament connector.
  13. Install the following parts:
    1. Rear spoiler (See REAR SPOILER REMOVAL/INSTALLATION .)
    2. Rear wiper motor (See REAR WIPER MOTOR REMOVAL/INSTALLATION .)
    3. Rear wiper arm and blade (See WINDSHIELD WIPER ARM AND BLADE REMOVAL/INSTALLATION .)
    4. High-mount brake light (See HIGH-MOUNT BRAKE LIGHT REMOVAL/INSTALLATION .)
    5. Liftgate lower trim (See LIFTGATE LOWER TRIM REMOVAL/INSTALLATION .)
    6. Liftgate side trim (See LIFTGATE SIDE TRIM REMOVAL/INSTALLATION .)
    7. Liftgate upper trim (See LIFTGATE UPPER TRIM REMOVAL/INSTALLATION .)
  14. Allow the sealant to harden completely.

    Sealant hardening time: 24 h 

  15. Apply soapy water to the rear window glass molding side and blow air from the interior, then verify that there are no bubbles or air leakage.
    • If there are any bubbles or air leakage, repair the damaged part of the sealant and verify it again.
scientia non olet · About LEMON Manuals