out HONDA CIVIC 1996 6.G Workshop Manual

'11.Thoroughly mix the adhesive and hardener together
on a glass or metal plate wilh a putty knife.
NOTE:
. Clean the plate with a sponge and alcohol before
mixing.
. Follow the instructions that came with the adhe-
sive.
Before filling a cartridge, cut the end of the nozzle
as shown.
10 mm {0.39 in.)
7 mm (0.27 in.l
Pack adhesive into the cartridge without air pockets
to ensure continous delivery. Put the canridge in a
caulking gun, and run a bead ol adhesive around
the edge of the rear window as shown.
NOTE| Apply the adhesive within 30 minutes after
applying the glass primer.
12.
13.
J
12 mm 10.,U in.)
[/ oo*r.,u.
8 mm (0.31 in.)
Make a slightly thickerbead at each corner.
GLASS
FASTENER
SPACER
MOLDING
MOLDING
)REAR WINDOW
FASTENER
20-35
14. Use suction cups to hold the rear window over the
opening, align it with the alignment marks made in
step 7, and set it down on the adhesive. Lightly
push on the rear window until its edges are {ully
seated on the adhesive all the way around.
NOTE: Do not open or close the doors until the adhe-
sive is dry.
SUCTION ALIGNMENTCUPS MARK
Scrape or wipe the excess adhesive off with a putty
knife or towel.
NOTE: To remove adhesive from a painted surface
or the rear window, use a soft shop towel damp-
ened with alcohol.
Let the adhesive dry for at least one hour, then
spray water over the rear window and check for
leaks. Mark the leaking areas, let the rear window
dry, then seal with sealant.
NOTE: Let the car stand for at least four hours after
rear window installation. lf the car has to be used
within the Iirst tour hours, it must be driven slowly
Reinstall all remaining removed parts
NOTE: Advise the customer not to do the following
things for two to three 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).
16.
1-7 .

tlnstallation
'1.
3.
Using a knife, scrape the old adhesive smooth to a
thickness of about 2 mm (0.08 in.) on the bonding
surface around the entire rear window opening
flange.
NOTE:
. Do not scrape down to the painted surface ol the
body; damaged paint will interfere with proper
bonding.
a Remove the rubber dams, spacers and fasteners
from the hatch.
. Mask off surrounding surfaces before applying
primer.
Clean the hatch bonding surface with a sponge
dampened in alcohol.
NOTE: After cleaning, keep oil, grease or water
from getting on the surface.
lf the old rear window is to be reinstalled, use a
putty knife to scrape off all traces of old adhesive,
then clean the rear window surface with alcohol
where new adhesive is to be applied.
NOTE; Make sure the bonding surface is kept free of
water, oil and grease.
CAUTION: Avoid setting the rear window on its
edges; the molding can be permanently deformed.
NOTE: Clean the shadowed area
2.
O
)
REAR WINDOW
4. Glue the rubber dams to the inside face of the rear
window, as shown, to contain the adhesive during
installation, and glue the fasteners, spacer and seals
as shown.
NOTE:
. Glue the rubber dams using the printed dots as a
g u ide.
. Be careful not to touch the rear window where
adhesive will be aPPlied
>r Fastener, spacor and seallocations
A>,4B>, 1
SPACER
D> '2 'EAL B'W
/l
si
o.\6fif,", j
ryt48rq _ _ ,,/
-\l
19Pry/
FASTENER PRINTED DOTS
REAR WINDOW
MOLOING
(cont'd)
20-37
FASTENER
"-*^1
wAL.IGNMENT ]IIARKS _ _,/C>,2 SEAL A

3
t
9. With a sponge, apply a light coat of body primer to
the original adhesive remaining around the rear
window opening flange. Let the body primer dry for
at least 10 minutes.
NOTE:
. Do not apply glass primer to the body, and be care-
ful not to mix up glass and body primer sponges.
. Never touch the primed surfaces with your hands.
//////// ' acoV boay primer here.
11.
Thoroughly mix the adhesive and hardener together
on a glass or metal plate with a putty knife.
NOTE:
. Clean the plate with a sponge and alcohol before
mlxlng.
. Follow the instructions that came with the adhe-
sive.
Before filling a cartridge, cut the end oJ the nozzle
as shown.
Cut nozzle
10.
I
10 mm {0.39 in.)
7 mm (0.27 in.)
12. Pack adhesive into the cartridge without air pockets
to ensure continuos delivery. Put the cartridge in a
caulking gun, and run a bead of adhesive around
the edge of the rear window as shown.
NOTE: Apply the adhesive within 30 minutes after
applying the glass primer.
ffi;fr'L/:ADHEs'vE
8mm{0.31 in.l
GLASS
MOLDING
GLASS ,R1---$
f\+,,","
ffi-f to.oa in.t
-.17MoLD|NG / \
(cont'd)
20-39

Rear WindowOuarter Glass
Installation {cont'd)
13. Use suction cups to hold the rear window over theopening. align it with the alignment marks made inslep 6. and set it down on the adhesive. Lightly pushon the rea. window until its edges are fully seatedon the adhesive allthe way around.
NOTE: Do not open or close the doors until the adhe_sive is drv.
sucTtoNCUPS
Scrape or wipe the excess adhesive off with a puttyknife or towel.
NOTE: To remove adhesive from a painted surfaceor the rear window. use a soft shop towel damp-ened with alcohol.
Let the adhesive dry for at least one hour. thenspray water over the rear window and check forleaks, Mark the leaking areas, let the rear windowdry, then seal with sealant.
NOTE: Let the car stand for at least four hours afterrear window installation. lf the car has to be usedwithin the first four hours, it must be driven slowly.
Reinstall all remaining removed parts.
NOTE: Advise the customer not to do the followingthings for two to three days:
. Slam the doors with all the windows rolled up.. Tr,vist the body excessively lsuch as when goingin and out of driveways at an angle or drivingover rough, uneven roads).
14.
15.
\
20-40
Removal
3D:
CAUTION:
a Pul on gloves to protect your hands.. Use seat covers to avoid damaging any surfaces,
1. To remove the quarter glass, first remove the:. Rear seat-back and rear seat cushion (see page20_80)
. Rear center shelf and rear side shelf lsee page20_60)
. Rear trim panel and side trim panel (see page20_60)
. Upper anchor bolts from the front and rear seatbelts {see pages 20-86. 89). Ouarter trim panel (see page20-60)
2, From inside the car, use a knife to cut through thequarter glass adhesive all the way around.
NOTE:
. lf the clip on the rear edge is broken, the quarterglass can be reinstalled using butyltape (see page20-421.
. Apply protective tape along the edge of the entirequarter glass opening flange.
OUARTERGLASS

Uppcr portion:
Lower oortion:
PROTECTIVETAPE
l
ADHESIVE
Pillar portion:
Carefully remove the quarter glass
NOTE: Check the quarter glass trim and clips for
damage, and replace them if necessary'
3.
)
AOHESIVE
TAPE
CLIP
lnstallation
1.Using a knife, scrape the old adhesive smooth to a
thickness of about 2 mm (0.08 in.) on the bonding
surtace around the entire quarter glass opening
flange.
NOTE:
. Do not scrape down to the painted surface of the
body; damaged paint will interfere with proper
bonding.
r Remove the rubber dams from the body.
. lf any of the clips are broken, remove them from
the body.
. Mask off surrounding surfaces before applying
pnmer.
Clean the body bonding surface with a sponge damp-
ened in alcohol.
NOTE: Afier cleaning, keep oil, grease and water
from getting on the surface.
lf the quarter glass is to be reinstalled, use a putty
knife to scrape off all traces of old adhesive. then
clean the quaner glass surface with alcohol where
adhesive is to be apPlied.
NOTE: Make sure the bonding surface is kept free
of water, oil and grease.
CAUTION: Avoid setting the quarter glass on its
edges; small chips may later devglop into cracks.
NOTE: Clean rhe shadowed area.
(cont'd)
20-41

Ouarter Glass
Installation (cont'd)
11. Pack adhesive into the cartridge without air pockets
to ensure continuous delivery. put the canridge in acaulking gun, and run a bead of adhesive aroundthe edge of the quarter glass as shown.
NOTE:
. lf the old quarter glass is to be reinstalled, peelthe separator off the butyl tape after applying theadhesive.
. Apply the adhesive within 30 minutes after apply_ing the glass primer.
i:.8i".,1/:ADHES,'E
8 rnm(0.31 in.l
OUARIERGLASS TRIM
OUARTERGLASS TFIM
BUTYI.TAPE
OUARTER GLASS
[-4m,^,GLASS \
32 mm{1.3 in.)
''='I
'"r"\
/ drt".GLASS TAPE
20-44
12. Use suction cups to hold the quarter glass over theopening, align the clips, and set it down on the adhe-sive. Lightly push on the quaner glass until its edgesare fully seated on the adhesive all the way around.
NOTE: Do not open or close the doors until theadhesive is drv.
Scrape or wipe the excess adhesive off with a puttyknife or towel.
NOTE: To remove adhesive from a painted surfaceor the quarter glass, wipe with a soft shop toweldampened with alcohol.
Let the adhesive dry for at least one hour, thenspray water over the quarter glass and check forleaks. Mark the leaking areas, let the quarter glass
dry, then seal with sealant.
NOTE: Let the car stand for at least four hours afterquarter glass installation. lf the car has to be usedwithin the first four hours, it must be driven slowly.
Reinstall all remaining removed parts.
NOTE: Advise the customer not to do the followingthings for two to three days:
. Slam the doors with all the windows rolled up.. Twist the body excessively (such as when goingan and out of driveways at an angle or drivingover rough, uneven roads).
15.
14.
CLIP

Ouarter Glass
1.
Installation
Using a knife, scrape the old adhesive smooth to athickness of about 2 mm (0.08 in.) on the bondingsurface around the entire quarter glass openingflange.
NOTE:
. Do not scrape down to the painted surface of thebody; damaged paint will interfere with proper
a
a
bonding.
Remove the fastener from the body.lf any of the clips are broken, remove lhem fromthe body.
Mask off surrounding surfaces before applyingpnmer.
Clean the body bonding surface with a sponge dampened in alcohol.
NOTE: After cleaning, keep oil, grease and waterfrom getting on the surface.
lf the quarter glass is to be reinstalled, use a puttyknife to scrape off all traces of old adhesive. thenclean the quarter glass surface with alcohol whereadhesive is to be applied.
NOTE: Make sure the bonding surface is kept freeof water. oil and grease.
CAUTION: Avoid setting the quarter glass on itsodges; small chips may later develop into cracks,
NOTE: Clean the shadowed area.
20-46
4. Install the molding around the edge of the quarterglass as shown.
NOTE:
. lf the old molding is to be reinstalled, scrape offthe old adhesive tape from the molding, andclean the molding surface with alcohol wherenew adhesive tape is to be applied. Apply thedouble-faced adhesive tape to the molding andquarter glass as shown.. Be careful not to touch the quarter glass whereadhesive will be aoDlied.
Adhesiv€ tspe A (3M 4215, or equivalent)Thicknsss: o.il mm (0.02 in.l
Widih: 5 mm {0.2 in.}
Length: /140 mm {17.3 in.)
Adhesive tap6 I (NITTO 501, or equivatontlThickness: 0.16 mm {0.006 in.)
Width: I mm {0.3 in.}
Longlh: 4it0 mm (17.3 in.)
Adhosiv€ tape C (3M /P13. or equivalentl
Thickness: 0.8 mm (0.03 in.l
Width: 5 mm (0.2 in.)
Length: 30 mm (1.2 in.)
ADHESIVE

Ouarter Glass
Installation (cont'dl
8. With a sponge, apply a light coat of body primer tothe original adhesive remaining around the quarter
glass opening flange. Let the body primer dry for atleast l0 minutes.
NOTE:
. Do not apply glass primer to the body, and becareful not to mix up glass and body primer
sponges.
. Never louch the primed surfaces with your hands.. Mask off the rear side trim panel before painting
the flange.
///ffi : Appty aoay primer here.
16 mm10.63 in.l
Thoroughly mix the adhesive and hardener togeth-er on a glass or metal plate with a putty knife.
NOTE:
. Clean the plate with a sponge and alcohol beforemixing.
. Follow the instructions that came with the adhe-sive.
Before filling a cartridge, cut the end of the nozzle
as shown.
Cul nozzle end
10 mrn (0.39 in.)
9.
10.
20-4A
7 mm 10.27 in.)
l'1. Pack adhesive into the canridge without air pockets
to ensure continuous delivery. Put the cartrige in a
caulking gun, and run a bead of adhesive around
the edge of the quarter glass as shown.
NOTE:
. lf the old quarter glass is to be reinstalled, peel
the separator off the butyl tape after applying theadhesive.
. Peel the separator off the adhesive tape afterapplying the adhesive.
. Apply the adhesive within 30 minutes after applying the glass primer.
12mm 11
lo.tt tn.l I l:ADHESIVE
8mm{0.31 in.)
CLIP
MOLDING

}
12. Use suction cups to hold the quarter glass over the
opening, align the clips, 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 the doo.s until the
adhesive is dry.
Scrape or wipe the excess adhesive off with a putty
knife or towel,
NOTE: To remove adhesive from a painted surface
or the quaner glass, wipe with a soft shop towel
dampened with alcohol.
Let the adhesive dry for at least one hour, then
spray water over the quarter glass and check for
leaks. Mark the leaking areas, let the quarter glass
dry, then seal with sealant.
NOTE: Let the car stand for at least four hours after
quarter glass installation. lf the car has to be used
within the first four hours, it must be driven slowly
Reinstall all remaining removed parts-
NOTE: Advise the customer not to do the following
things for two to three 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 roadsl.
13.
14.
)
CLIP
a
20-49

Troubleshooting
SymptomProbable Cause
Water leaks1. Clogged drain tube.
2. Gap between glass weatherstrjp and roof panel.
3. Defective or improperly installed glass weatherstrip.
4. Gap between drain seal and roof panel.
Wind noise'1. Excessive clearance between glass weatherstrip and roof panel.
Motor noise1. Loose motor.
2. Worn gear or bearing.
3. Cable assembly deformed.
Glass does not move, but motor turns'1. Clutch out of adjustment.
2. Foreign matter stuck between guide rail and slider.
3. lnner cable loose.
4. Cable assembly not attached properly.
Glass does not move and motor does not turn
{glass can be moved with moonroof wrench)
1. Blown fuse,
2. Faulty switch.
3. Battery run down.
4. Defective motor.
5. Faulty relay.
D
Glass Height Adjustment
The roof panel should be even with the glass weather-
strip, to within 1.7 :lr3 mm (0.07 :3:31 in.) all the way
around. lf not, open the giass fully, and:
GLASS WEATHERSTRIP
1. Remove the bracket cover.
Loosen the nuts, and install the shims between the
glass frame and glass bracket as shown.
Shim thickness: Front max.3 mm 10,12 in.l
Rear max. 2 mm 10.08 in.)
Repeat on opposite side i{ necessary.
)
5x1.0mm9.8 N.m 11.0 kgf m,7.2 rbtft)
SRACKETCOVEB
----------1>
6x1.0mm9.8 N.m {1.0 kgtm,7.2 tbf.ft)
1.7 tl.8 mm
{0.07 :3 3i in.}
20-51