LEMON Manuals: Even more car manuals for everyone
Home >> Mazda >> 2005 >> 3 i, Automatic >> Repair and Diagnosis >> Body & Frame >> Glass/Windows/Mirrors >> Rear Window Glass Installation >> 4 Door

4 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.
    Fig 1: Cutting Sealant From Rear Window Frame
    G03637048Courtesy of MAZDA MOTORS CORP.
  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.
  4. If installing a reused rear window glass, install the rear window glass molding according to the following procedure.
    1. Clean and degrease the rear window glass molding installation area of the rear window glass.
    2. Apply the glass primer to the rear window glass molding installation area of the rear window glass.
    Fig 2: Installing Rear Window Glass Molding - 4 Door
    G03637049Courtesy of MAZDA MOTORS CORP.
  5. 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: Applying Glass Primer To Rear Window Glass & Window Frame - 4 Door
    G03637050Courtesy of MAZDA MOTORS CORP.
  6. Apply sealant to the glass surface as shown in the figure.
    Fig 4: Identifying Proper Sealant Application - 4 Door
    G03637051Courtesy of MAZDA MOTORS CORP.
  7. Insert the positioning pins into the body, then install the rear window.
  8. Press the rear window pins to engage the tabs to the body.
    Fig 5: Ensuring Rear Window Pins Engagement - 4 Door
    G03637052Courtesy of MAZDA MOTORS CORP.
  9. Press completely along the perimeter of the glass so that the measurement of the molding lip gap is within the specification.
    Fig 6: Measuring Rear Window Molding Gap - 4 Door
    G03637053Courtesy of MAZDA MOTORS CORP.
  10. Connect the filament connector.
  11. Install the following parts:
    1. Rear package trim (See REAR PACKAGE TRIM REMOVAL/INSTALLATION .)
    2. C-pillar trim (See C-PILLAR TRIM REMOVAL/INSTALLATION .)
    3. Tire house trim (See TIRE HOUSE TRIM REMOVAL/INSTALLATION .)
    4. Rear scuff plate (See REAR SCUFF PLATE REMOVAL/INSTALLATION .)
    5. Rear seat (See REAR SEAT REMOVAL/INSTALLATION )
  12. Allow the sealant to harden completely.

    Sealant hardening time: 24 h 

  13. 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