Rear Window Glass Installation

WARNING: This page is about a different car, the 2004 Mazda RX-8. However, it is still accessible from the selected car via links, so may be relevant.

CAUTION:

Proper installation of the windshield 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.

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.
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.
Clean and decrease the perimeter approx. 50 mm {2.0 in} from the glass end and the bonding area on the body.
If installing a reused rear window glass, perform the following procedure:
1. Clean and decrease the rear window molding installation area of the rear window glass.
2. Apply the glass primer to the rear window molding installation area of the rear window glass.
3. Remove the remaining double-sided adhesive tape from the rear window molding, and install the rear window molding (upper) to the rear window glass while aligning the molding with the center of the marking on the glass.
  
  Fig 1: Installing Rear Window Molding (Lower)
  Courtesy of MAZDA MOTORS CORP.
  NOTE:
  - Double-sided adhesive tape has been affixed to the new rear window molding.
4. Install the rear window molding (lower).
5. Apply the glass primer to the inside of the rear window molding at the joint between the upper and lower parts.
  
  Fig 2: Applying Tape To Inside Of Rear Window Molding At Joint
  Courtesy of MAZDA MOTORS CORP.
6. Affix the tape to the inside of the rear window molding at the joint.
7. Install the dam by aligning its end with the center of the marking on the glass. See Fig 3 .
  
  Fig 3: Installing Dam By Aligning End With Center Of Marking On Glass
  Courtesy of MAZDA MOTORS CORP.
8. Attach the pins to the seating positions where marked during removal.
Place a mark at the point on the rear window glass indicated in the figure.

Fig 4: Placing Mark At Point On Rear Window Glass
Courtesy of MAZDA MOTORS CORP.
Use only glass primer on the rear window glass, and body primer on the rear window molding as shown in the figure. Allow it to dry for approx. 30 min.
CAUTION:
- Keep the area free of dirt, water and grease, and do not touch the surface. Otherwise, the primer may not properly bond to the surface of the glass and body, causing leaks to occur.
Fig 5: Measuring Area Of Primer Application
Courtesy of MAZDA MOTORS CORP.
Apply sealant to the glass surface. See Fig 6 .

Fig 6: Applying Sealant To Glass Surface
Courtesy of MAZDA MOTORS CORP.
Position the marking on the rear window glass and the curved line of the body (roof molding) left and right so that they are aligned.

Fig 7: Positioning Marking On Rear Window Glass And Curved Line Of Body (Roof Molding)
Courtesy of MAZDA MOTORS CORP.
Insert the pin into the body (1), and lower the rear part (2).

Fig 8: Inserting Pin Into Body (1), And Lower Rear Part (2)
Courtesy of MAZDA MOTORS CORP.
NOTE:
- If the rear window glass is tilted while inserting the pin into the body, the sealant will rub against the body flange, causing damage to the sealant. Do not tilt the rear window glass to the left or right while working.
Press the pins and engage the tabs to the body.
Press the rear window glass at (a) shown in the figure from the rear of the vehicle so that the measurement of the rear window molding lip gap is within specification.
CAUTION:
- If any sealant adheres to the antenna and/or filament, be sure to wipe it off.
Fig 9: Measuring Rear Window Molding Lip Gap
Courtesy of MAZDA MOTORS CORP.
Install the nut.

Fig 10: Connecting Antenna And Filament Connectors
Courtesy of MAZDA MOTORS CORP.
Connect the antenna and the filament connectors.
Install the following parts:
1. Rear package trim (See REAR PACKAGE TRIM REMOVAL/INSTALLATION .)
2. Rear pillar trim REAR PILLAR TRIM REMOVAL/INSTALLATION .)
3. Tire house trim (See TIRE HOUSE TRIM REMOVAL/INSTALLATION .)
4. Rear seat (See REAR SEAT REMOVAL/INSTALLATION .)
Allow the sealant to harden completely.
Sealant hardening time: 24 h
Apply soapy water to the rear window 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.