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Glass, Sunroof: Installation

CAUTION:

Open the left front door glass before installing the rear window to avoid pressurizing the passenger compartment if a door is slammed before the urethane bonding is fully cured. Water leaks can result.

CAUTION:

Do not operate the vehicle within 24 hours of backlight installation. It takes at least 24 hours for urethane adhesive to cure.

CAUTION:

Protect all exposed painted and trimmed surfaces from coming in contact with urethane and primers

GC0103352Courtesy of CHRYSLER GROUP, LLC
  1. Before proceeding with the following repair procedure, review all warnings and cautions. Refer to STATIONARY GLASS, WARNING .
  2. If the rear sunroof glass (1) is being reused, with the use of a razor knife (2), level the remaining urethane bead down to approximately 1 mm (.04 in.),
    GC0158616Courtesy of CHRYSLER GROUP, LLC
  3. Using a razor knife, level the remaining urethane bead (2) down to approximately 1 mm (.04 in.) on the sunroof frame.
  4. Inspect glass spacers (1) and replace and position any missing and damaged spacers.
  5. Replace the antenna adhesive seal (3).
    GC0159072Courtesy of CHRYSLER GROUP, LLC
  6. Inspect the rear glass weatherstrip (3). If damaged or missing follow the proceeding-
    1. If reusing the rear sunroof glass (4), remove the weatherstrip and clean any remaining tape residue off of the glass.
    2. Wipe the attachment area with a clean, lint-free cloth, moistened with a 50% solution of water and alcohol.
    3. Dry the area immediately, with a lint free cloth.
      NOTE:

      If ambient temperature is below 21° C (70° F), warm the glass and weatherstrip. Do not exceed 32° C (90° F).

    4. Align the new weatherstrip (3) to the glass (4), gradually remove the protective backing and firmly press the weatherstrip (3) to the glass (4).
    GC0159049Courtesy of CHRYSLER GROUP, LLC
  7. Install the liftgate spoiler to be certain of proper gap and flush dimensions. Refer to SPOILER, INSTALLATION .
  8. Install the front sunroof glass to be certain of proper gap and flush dimensions. Refer to GLASS, SUNROOF, INSTALLATION .
  9. Position the front sunroof glass in the fully closed position.
  10. Inspect the front sunroof glass for proper alignment and adjust if necessary. Refer to GLASS, SUNROOF, FRONT, ADJUSTMENTS .
    GC0158637Courtesy of CHRYSLER GROUP, LLC
  11. With the help of an assistant, trial fit the rear sunroof glass (3).
    NOTE:

    Flush (height) measurements must take into account the additional height of the urethane bead.

  12. Align the sunroof rear glass as follows:
    • Body sides to rear sunroof glass (1)- Gap- centered symmetrically
    • Front sunroof glass to rear sunroof glass (5)- Gap 5 mm ± 2 mm / Over Flush 1 mm + 1.5 mm - 1 mm
    • Rear sunroof glass to liftgate spoiler (3)- Gap 6.5 mm ± 1.4 mm / Over Flush 0.5 mm ± 1.8 mm
  13. Use masking tape (4) to mark the alignment of the rear sunroof glass (2) to the adjoining panels. Cut the strips of masking tape along the perimeter of the sunroof glass.
  14. Remove the rear sunroof glass (2).
  15. Touch up any damaged paint.
    GC0103355Courtesy of CHRYSLER GROUP, LLC
  16. Clean the sunroof frame and the rear stationary sunroof glass with an ammonia based glass cleaner and a lint-free cloth.
    NOTE:

    Refer to the adhesion promoter and primer manufacturer's recommendation for application and dry times.

  17. Apply a glass adhesion promoter where the urethane bead will be applied to the sunroof rear glass.
  18. Allow to dry per manufacturer recommendations.
  19. Apply a urethane primer where the urethane bead will be applied to the sunroof rear glass and where it will contact the sunroof frame.
  20. Allow to dry per manufacture recommendations.
  21. Using a flashlight, verify that the primer is completely and evenly installed along the rear sunroof glass.
  22. Re-prime any area that is not fully and evenly primed.
    GC0159072Courtesy of CHRYSLER GROUP, LLC
  23. Apply a 1.5 cm (3/8 in.) bead of urethane (1) to the rear sunroof glass (4) where indicated.
  24. For the perimeter bead of urethane, start and finish a the rear of the glass (2), with the bead overlapping.
  25. With the help of an assistant, place the rear stationary sunroof glass to the vehicle and align to the marks previously made.
  26. Align to proper gap and flush dimensions.
    GC0158897Courtesy of CHRYSLER GROUP, LLC
  27. Install the three nuts (1) securing the rear sunroof glass (2) to the sunroof frame crossmember (3).
  28. If necessary, apply retaining straps to keep sunroof assembly at described position.
  29. Allow urethane to dry per manufacturer directions.
  30. Install the satellite antenna. Refer to ANTENNA, SATELLITE, INSTALLATION .
  31. Before installing the interior perform a water leak test.
  32. Install the sunshade. Refer to SUNSHADE, SUNROOF, INSTALLATION .
  33. Install the satellite antenna. Refer to ANTENNA, SATELLITE, INSTALLATION .
  34. Install the headliner. Refer to HEADLINER, INSTALLATION .
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