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Honda Odyssey 2004. Manual - part 351

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20-46

Glass

Rear Window Replacement (cont’d)

Fastener Locations

: Fastener, 2

3 mm
(0.12 in.)

7. With a putty 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:

• Do not scrape down to the painted surface of the

body; damaged paint will interfere with proper
bonding.

• Remove the fasteners from the tailgate.

8. Clean the tailgate bonding surface with a sponge

dampened in alcohol. After cleaning, keep oil,
grease and water from getting on the surface.

9. If the old rear window will be reinstalled, use a

putty knife to scrape off all of the old adhesive and
rubber dam from the rear window. Clean the
shaded portion of the rear window (A) with alcohol
where new adhesive is to be applied. Make sure the
bonding surface is kept free of water, oil and
grease.

10. Attach the upper corner fasteners (A) and lower

corner fasteners (B) with adhesive tape (3M 5312,
or equivalent). Attach the upper spacer (C) and
lower rubber dam (D) with adhesive tape (NITTO
501M, or equivalent) to the inside surface of the
rear window (E) as shown:

• Be sure the fasteners, upper spacer and rubber

dam line up with alignment marks (F).

• Be careful not to touch the rear window where

adhesive will be applied.

03/07/29 10:00:29 61S0X050_200_0048

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20-47

Fastener Locations

Fastener, 2

: Apply glass primer here.

12 mm (0.47 in.)

7 mm
(0.28 in.)

10 mm
(0.39 in.)

2 mm
(0.08 in.)

12 mm (0.47 in.)

11. Attach the upper corner fasteners (A) and lower

corner fasteners (B) with adhesive tape (3M 5312,
or equivalent) to the tailgate as shown.

12. Set the rear window in the opening, and center it.

Make alignment marks (A) across the rear window,
tailgate and body with a grease pencil at the four
points shown. Be careful not to touch the rear
window where adhesive will be applied.

13. Remove the rear window.

14. With a sponge, apply a light coat of glass primer

along the edge of the rear window (A) lower rubber
dam (B) as shown, then lightly wipe it off with
gauze or cheesecloth:

• With the printed dots (C) on the rear window as a

guide, apply the glass primer to both side
portions of the rear window.

• Do not apply body primer to the rear window,

and do not get tailgate and glass primer sponges
mixed up.

• Never touch the primed surfaces with your hands.

If you do, the adhesive may not bond to the rear
window properly, causing a leak after the rear
window is installed.

• Keep water, dust, and abrasive materials away

from the primed surface.

(cont’d)

03/07/29 10:00:29 61S0X050_200_0049

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20-48

Glass

Rear Window Replacement (cont’d)

20 mm (0.79 in.)

9 mm (0.35 in.)

20 mm
(0.79 in.)

2 mm (0.08 in.)

20 mm
(0.79 in.)

: Apply body primer here.

10 mm (0.39 in.)

7 mm (0.27 in.)

2 mm (0.08 in.)

9 mm (0.35 in.)

13 mm
(0.51 in.)

2 mm (0.08 in.)

8 mm (0.31 in.)

15. 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:

• Do not apply glass primer to the body, and be

careful not to mix up glass and body primer
sponges.

• Never touch the primed surfaces with your hands.

16. Before filling a cartridge with adhesive, cut a ‘‘V’’ in

the end of the nozzle (A) as shown.

17. Pack adhesive into the cartridge without air pockets

to ensure continuous delivery. Put the cartridge in a
caulking gun, and run a bead of adhesive (A)
around the edge of the rear window (B) as shown.
With the printed dots (C) on the rear window as a
guide, apply the adhesive to both side portions of
the rear window.
Apply the adhesive within 30 minutes after
applying the glass primer. Make a slightly thicker
bead at each corner.

03/07/29 10:00:30 61S0X050_200_0050

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20-49

Sliding Door Glass Replacement

18. Use suction cups (A) to hold the rear window over

the opening, align it with the alignment marks (B)
you made in step 12, and set it down on the
adhesive. Lightly push on the rear window until its
edges are fully seated on the adhesive all the way
around. Do not open or close the doors until the
adhesive is dry.

19. Scrape or wipe the excess adhesive off with a putty

knife or towel. To remove adhesive from a painted
surface or the rear window, use a soft shop towel
dampened with alcohol.

20. Let the adhesive dry for at least 1 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. Let the vehicle stand for at
least 4 hours after rear window 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).

NOTE:

• Put on gloves to protect your hands.
• Use seat covers to avoid damaging any surfaces.
• Wear eye protection while cutting the glass adhesive

with piano wire.

1. Remove the sliding door panel (see page 20-13).

2. Remove the upper seal (A) and molding (B) from

the edge of the glass (C). If necessary, cut the upper
seal and molding with a utility knife.

(cont’d)

03/07/29 10:01:33 61S0X050_200_0051

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