Replacing rear windshield, 4-door: Removal

Remove: 

• The stop lamp
• Release upper edge of D-post panel to permit access to wiring connectors (the panel need not be removed).
• Bend forward and disconnect the rear windshield wiring connectors.

Mask the body around the glass with tape to prevent paint damage 

Use piano wire, handle and counterhold. See: .

Fig 1: Using Round-Nosed Pliers To Pull Wire Through From Outside

Courtesy of VOLVO CARS OF NORTH AMERICA.

Cut out the glass 

• Start in the top corner and cut downwards.
• At corners, work from other direction when approximately 1/4  remains
• "Saw" around the corner
• Ensure that the wire does not catch on the heated rear windshield terminal pins.

  Keep the wire tensioned the whole time.

Fig 2: Removing Weatherstrip At Upper Edge Of Windshield

Courtesy of VOLVO CARS OF NORTH AMERICA.

• Pull the counterhold along the lower edge

  Ensure that the wire is free of the metal clips for the parcel shelf

• Keep the counterhold pressed against the PUR adhesive at all times.
• Apply suction pads to the glass.

  Lift out and place it on the stand.

• Leave the remaining PUR adhesive residue on the body flange

If the glass is to be reused: Cut away the remaining PUR bead using a chisel