Caution
Always wear heavy gloves and safety glasses when handling glass to minimize
the risk of injury.
Notice
Place protective covers on body to prevent paint damage.
Important
Both body lock pillar upper moldings must be removed.
- Remove the rear window trim finish panel. Refer to
Finish Panel Replacement - Upper Rear Trim
in Interior Trim.
- Remove the center high-mount stop lamp cover.
- Remove the fasteners from the center high-mount stop lamp and disconnect
the wire connector.
- Lower the rear half of the headliner. Use lightweight wood or foam blocks
to hold the headliner down.
- Remove the electrical connectors from the bus bars, rear window defogger.
Locate the electrical connectors so as not to damage the wiring/connectors when
using the urethane power removal tool.
- Remove the roof side outer rear panel. Refer to
Roof Side Outer Rear Panel Replacement
in Roof.
- Remove the quarter panel fasteners at the lock pillar and the upper gutter area.
Use lightweight wood or foam blocks to hold the quarter panel out.
Caution
When using power tools that may create smoke when cutting urethane sealant,
work should be done in a well ventilated area and/or with a NIOSH/MSHA Approved air
supplied respirator to prevent possible harmful exposure.
When the urethane adhesive is heated enough to give off smoke, high levels of
methylene diisocyanate (MDI) may be present.
Unprotected exposure to methylene diisocyanate (MDI) may result in severe, chronic,
debilitating respiratory problems.
Notice
Care must be taken not to damage the roof when using power glass removal tool.
- With the power glass removal tool, cut the urethane seal along
the roof, down the sides and along the rear window lower panel between the rear
compartment lid hinges from inside of the vehicle.
- Use piano wire to cut the urethane at the lower corners. Feed the wire
under the glass at the C-pillar through the inside and back out at the rear window
lower panel, then around the outside of bead. Use a sawing motion to cut the urethane.
- With the aid of a helper, remove the window assembly.
- Remove the old urethane with a razor knife leaving a thin film, approximately
1-2 mm (0.04-0.08 in) around the perimeter of the window
opening and the window assembly, if being reused.
Notice
Loose material and/or a rough surface on remaining urethane may cause sealing
problems during installation.
Important
The glass anti-slide clips will be damaged in the removal process. Make certain
the anti-slide clips are replaced with new service parts. Do not slide the adjuster
upward until the window assembly is installed.
- Clean the entire window opening and glass bonding surfaces with a clean lint-free,
alcohol dampened cloth. Allow to air dry.
Important
If applied molding becomes loose from the edge of the glass, clear and black
prime the affected area. Allow to air dry. Apply a thin bead of urethane and install
the molding.
Notice
To prevent corrosion, paint damage around the window opening by the power glass
removal tool must be covered with pinchweld primer. Do not prime over
existing urethane. Follow manufacturers recommendations for drying time.
Notice
To avoid damage to the outer edge of the glass, be careful not to scratch the
glass when removing urethane with a razor blade.
Notice
Loose urethane and/or rough surfaces may cause sealing problems during installation.
For cars with a sunroof, it is important to install the fasteners to the new
roof assembly before the roof is installed in place.
- Preparation for window installation:
- Tape the rear compartment lid in a half open position to provide clearance
for installing the glass.
- Prime the window opening area.
- Shake the glass primer, Black #2 or equivalent, well before applying.
Important
The primer area has a minimum width diameter of 18 mm (0.71 in)
in area (A) area.
Important
Use the line along the top of the rear window assembly below the rear window
assembly upper molding as a guide when applying primer.
- With a new dauber apply the glass prep primer , Black #2 or equivalent,
around the entire perimeter over Clear #1, or equivalent.
- Allow the primer to dry 5 minutes before applying the urethane.
- Apply a smooth and continuous bead of adhesive directly to the old urethane
adhesive in the glass opening or to the glass. Apply according to the following
dimensions:
Bead Dimension
- Minimum Width: Dimension (B) 10 mm (0.39 in).
- Minimum Height: Dimension (C) 14 mm (0.55 in).
- With the aid of a helper, lift the glass into the window opening. Use
the notches in the roof panel to center the glass to the vehicle. Make certain the
lip of the applied molding laps over the roof feature line.
Notice
Until the new urethane has cured, air pressure from a closing door may cause
the glass to move. To prevent this, lower the opposite side door window
a minimum of 76 mm (3 in) before closing the door.
- Slide the adjuster on the anti-slide clips upward to position the glass up/down.
Important
The vehicle must remain at normal room temperature for 6 hours to complete
proper cure of the adhesive. Refer to the manufacturer's recommendation.
- Press the glass firmly to wet-out and set adhesive. Use care to avoid excessive
squeeze out which would cause an appearance problem. Using duct tape or equivalent,
tape glass up to the roof.
- Watertest the vehicle at once using a soft spray. Use warm or hot water
if available. Do not direct a hard stream of water on fresh adhesive material. Water
applied on top of urethane adhesive, either during watertest or part of a separate
operation, will speed up the cure of urethane.
Notice
Refer to Fastener Notice in Cautions and Notices.
- Inspect for leaks from inside the vehicle. Paddle in extra adhesive at
leak points using a tongue depressor or similar flat flexible tool.
- Install the quarter panel fasteners.
TightenTighten the fasteners to 9 N·m (80 lb in).
- Install the roof
side outer rear panel. Refer to
Roof Side Outer Rear Panel Replacement
in Roof.
- Connect the electrical connectors to bus bar.
- Install the headliner.
- Install the center high-mount stop lamp.
- Install the center high-mount stop lamp cover.
- Install the rear window trim finish panel. Refer to
Finish Panel Replacement - Upper Rear Trim
in Interior Trim.