Removing the rear windshield

WARNING: This page is about a different car, the 2004 Volvo S40, 2003 Volvo S40, 2002 Volvo S40, 2001 Volvo S40, and 2000 Volvo S40. However, it is still accessible from the selected car via links, so may be relevant.

Remove:

the high-level stop lamp. See Changing the high-mounted brake light
the rubber strip on the inside
the wiper arm mechanism. See Tailgate wiper mechanism and motor
the electrical terminals for the heated rear windshield
the rear panel
the tail lamp unit. See Replacing tail lamps (5 doors) .

Push the wire through the PUR adhesive bead. Cut out the rear windshield in the same way as for the front windshield.

NOTE:

Apply masking tape to the painted bodywork.

Install the window:

Check the PUR-bead on the tailgate. Even out using a chisel if necessary. A layer of approximately 1 mm can be left. Clean using Cleaner-H.

Check and replace (if necessary) the four spacers on the frame.

Cut away the PUR bead using a chisel if the window is to be reused.

Use glass activator to clean the area on which the PUR adhesive is to be applied. A layer of approximately 1 mm can be left.

Apply glass primer to the surface. Apply liberally without allowing to run. Let the primer dry until the surface is matte.

Remove the masking tape.

NOTE:

Install a new inner rubber. Check that the rubber is not in contact with the windshield at any point. Adjust the flange if the rubber is against the windshield.

Fig 1: Installing Weatherstrip

Courtesy of VOLVO CARS OF NORTH AMERICA.

Install the trim strips. Bond the new trim strip approximately 5 mm from the outer edge and approximately 1 mm from the upper and the lower edges respectively. Install the trim strip. Start at the marker in position (A) on the left and right on the upper side of the rear windshield flange.

Install the weatherstrip.

Start at the marking (A) on the left and right-hand sides on the top of the rear windshield flange.

Apply PUR adhesive to the glass.

Install the windshield. Secure the windshield to the roof using a couple of pieces of tape.

Shut the tailgate completely before installing the windshield.

Install:

the tailgate wiper motor. See Tailgate wiper mechanism and motor
the wiper arm and the wiper blade. See Tailgate wiper mechanism and motor
the electrical terminals for the heated rear windshield
the high-level stop lamp. See Changing the high-mounted brake light
the tail lamp unit and the rear windshield panel. See Replacing tail lamps (5 doors) .