Rear Window Assembly
REAR WINDOW ASSEMBLY - COUPEREMOVAL
CAUTION: ALWAYS WEAR HEAVY GLOVES AND SAFETY GLASSES WHEN HANDLING GLASS TO MINIMIZE THE RISK OF INJURY.
NOTE: Place protective covers on body to prevent paint damage.
1. Remove rear window trim finish panel.
IMPORTANT: Both body lock pillar upper moldings must be removed.
2. Remove center high mount stop lamp cover.
3. Remove fasteners from center high mount stop lamp housing and disconnect wire connector.
4. Lower rear half of headliner. Use lightweight wood or foam blocks to hold headliner down.
5. Remove electrical connectors from bus bars.
6. Remove rear compartment lid weatherstrip at package shelf.
7. Remove roof outer drip rail.
8. Remove Taillamps and disconnect wire connectors.
9. Remove quarter panel fasteners at lock pillar, Taillamp opening, and upper gutter area. Use lightweight wood or foam blocks to hold 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 DI-ISOCYANATE (MDI) MAY BE PRESENT.
UNPROTECTED EXPOSURE TO METHYLENE DI-ISOCYANATE (MDI) MAY RESULT IN SEVERE, CHRONIC, DEBILITATING RESPIRATORY PROBLEMS.
NOTE: Care must be taken not to damage the roof when using power glass removal tool. If necessary, tape off body around glass with thick tape.
10. Using a power glass removal tool, cut urethane seal along roof from inside, and urethane seal along sides and bottom, from outside of vehicle.
11. Cut urethane seal on bottom comers, using piano wire as shown in illustration.
12. With aid of a helper, remove window assembly.
INSTALLATION
IMPORTANT: Loose urethane and/or a rough surface on remaining urethane may cause sealing problems during installation.
1. Remove old urethane with a razor knife leaving a thin film (approximately 1-2 mm) around the perimeter of window opening and window assembly (if being reused).
2. Tape decklid in half open position to provide clearance for installing glass.
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.
3. Clean the entire window opening and glass bonding surfaces with a clean, lint free, alcohol dampened cloth. Allow to air dry.
NOTE: To prevent corrosion, paint damage around the pinchweld flange by the power glass removal tool, must be covered with pinchweld primer. Do not prime over existing urethane. Follow manufacturer's recommendations for drying times.
4. New back glass only - Shake glass prep primer (Clear #1) well before using. Apply glass prep primer (Clear #1) around entire perimeter of glass using dauber. Wipe dry with a clean lint-free cloth.
Primer area (Minimum Width, A): 18 mm (0.71 in.)
Shake glass primer (Black #2) well before applying. With a new dauber apply glass prep primer (Black #2) around the entire perimeter over Clear #1. Allow primer to dry five minutes before applying urethane.
Primer area (Minimum Width, A): 18 mm (0.71 in.)
5. Apply a smooth continuous bead of adhesive around edge of glass per bead dimension and profile as shown.
Bead Dimension
Minimum Width - B: 13 mm (0.51 in.)
Minimum Height - C: 8 mm (0.32 in.)
6. With aid of a helper, lift glass into window opening. Align edge of glass with notch in roof panel. Make certain the lip of the applied molding laps over the roof feature line.
7. Slide the adjuster on the anti-slide clips upward to position glass up/down.
NOTE: Until the new urethane has cured, air pressure from a closing door may cause the backglass to move. To prevent this, lower one window a minimum of 76 mm (3 in.) before closing the door.
8. Press 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 roof.
IMPORTANT: Vehicle must remain at normal room temperature for 6 hours to complete proper cure of adhesive. Refer to manufacturer's recommendation.
9. Watertest vehicle at once using soft spray. Use warm or hot water if available. Do not direct hard stream of water at fresh adhesive material. Water applied on top of urethane adhesive, during watertest or as a separate operation, will speed up the cure of the urethane.
10. Inspect for leaks from inside vehicle. Paddle in extra adhesive at leak points using a tongue depressor or similar flat flexible tool.
11. In stall rear compartment lid weatherstrip.
12. Remove blocks that hold quarter panels outboard and install fasteners.
13. Install Taillamps.
14. Install roof outer drip rail.
15. Remove blocks used to hold headliner down.
16. Connect electrical connectors to bus bars.
17. Install rear window trim finish panel.