Honda Odyssey Service Manual: Quarter Glass Replacement

NOTE:

• Wear eye protection while cutting the glass with piano wire.

• Put on gloves to protect your hands.

• Use seat covers to avoid damaging any surfaces.

• Do not damage the antenna grid lines or terminals.

1. Remove these items:

   • Sliding door center rail cover

   • C-pillar trim

   • D-pillar trim

2. Remove the front seal (A) from the front edge of the quarter glass (B). If necessary, cut the rubber dam with a utility knife.

3. Disconnect the glass antenna terminal (A).

4. From inside the vehicle, cut through the quarter glass adhesive (A) with a utility knife (B) on the upper, lower and rear edges:

   • Apply protective tape along the edges of the entire quarter glass opening flange.

   • If the quarter glass (C) is to be reinstalled, take care not to damage the windshield molding (D).

   • If the molding is damaged, replace the quarter glass, the molding, and the clips (E) as an assembly.

5. Apply protective tape along the outside edge of the body. Push a piece of piano wire through the lower cut area in the adhesive, and wrap each end around a piece of wood.

6. With a helper on the outside, pull a piano wire (A) back and forth in a sawing motion. Hold the piano wire as close to the quarter glass (B) as possible to prevent damage to the body, and carefully cut through the adhesive (C) on the front side of the quarter glass.

   • Take care not to drop the quarter glass.

   • If the quarter glass is to be reinstalled, take care not to damage the quarter glass molding (D).

   • If the molding is damaged, replace the quarter glass, the molding, and the clips (E) as an assembly.

Cutting positions

7. Carefully remove the quarter glass.




8. Scrape the original adhesive smooth to a thickness of about 2 mm (0.08 in) on the bonding surface around the entire quarter glass opening flange with a putty knife:

   • Do not scrape down to the painted surface of the body; damaged paint will interfere with proper bonding.

   • Remove the clip and the fastener from the body.

9. Clean the body bonding surface with a shop towel dampened with isopropyl alcohol. After cleaning, keep oil, grease, and water from getting on the clean surface.

10. If you are reinstalling all of the original quarter glass with a putty knife to scrape off all of the original adhesive, the fastener and the rubber dam from the quarter glass. Clean the bonding surfaces on the inside face and the edge of the quarter glass with isopropyl alcohol. Make sure the bonding surface is kept free of water, oil, and grease.

11. Attach the front seal (A) with the adhesive tape (B) to the front edge of the quarter glass (C) as shown.

12. Set the quarter glass (A) in the opening, and center it. Make alignment marks (B) across the glass and the body with a grease pencil at the four points shown.

    NOTE: Be careful not to touch the quarter glass where the adhesive will be applied.

13. Remove the quarter glass.

    NOTE: Take care not to break the clips during removal.

14. Apply light coat of glass primer to the inside face of the quarter glass (A) along the quarter glass molding (B) as shown, then lightly wipe it off with gauze or cheesecloth:

    • Apply the glass primer to the corner area of the quarter glass using the printed dots (C) on the quarter glass as a guide.

    • Do not apply body primer to the quarter glass, and do not mix up the body and glass primer applicators.

    • Let the primer dry at least 10 minutes.

    • Never touch the primed surfaces with your hands. If you do, the adhesive may not bond to the quarter glass properly, causing a leak after the quarter glass is installed.

    • Keep water, dust, and abrasive materials away from the primed surface.

15. Carefully apply a light coat of body primer to any exposed paint or metal around the flange where the new adhesive will be applied. Let the body primer dry for at least 10 minutes:

    • Do not apply body primer to any remaining original adhesive on the flange.

    • Be careful not to mix up the body and glass primer applicators.

    • Never touch the primed surfaces with your hands.

16. Cut a ‘‘V'' in the end of the adhesive cartridge nozzle (A) as shown.

17. Put the cartridge in a caulking gun, and run a continuous bead of the adhesive (A) on the quarter glass (B) around the edge of the quarter glass molding (C) as shown:

    • Use the printed dots as a guide when you apply the adhesive to the corners of the quarter glass.

    • Apply the adhesive within 30 minutes after applying glass primer.

    • Make a slightly thicker bead at each corner.




18. Hold the quarter glass with suction cups over the opening, align it with the clips or the alignment marks made in step 12, and set it down on the adhesive. Lightly push on the quarter glass until its edges are fully seated on the adhesive all the way around.

    NOTE: Do not open or close any of the doors for about an hour until the adhesive is dry.

19. Remove the excess adhesive with a putty knife or a shop towel dampened with isopropyl alcohol.

20. Wait at least an hour for the adhesive to dry, then spray water over the quarter glass, and check for leaks. Mark the leaking area, and let the quarter glass dry, then seal with sealant. Let the vehicle stand for at least 4 hours after quarter glass installation. If the vehicle has to be used within the first 4 hours, it must be driven slowly.

21. Reinstall all remaining removed parts.

    NOTE: Advise the customer not to do the following things for 2 to 3 days:

    • Slam the doors with all the windows rolled up.

    • Twist the body excessively (such as when going in and out of driveways at an angle or driving over rough, uneven roads).