Rear Window Assembly
REMOVALCAUTION: 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 center high mount stop lamp cover.
2. Unsnap center high mount stop lamp from roof and disconnect wire connector.
3. Lower rear half of headliner. Use lightweight wood or foam blocks to hold headliner down.
4. Remove molding around rear window carefully trying not to excessively stretch it.
5. Remove electrical connectors from rear window defogger bus bars. Locate electrical connectors and mark location both inside and outside of window with tape so as not to damage wiring/connectors when using power glass removal tool.
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.
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.
6. With power glass removal tool, cut urethane seal along roof, down the sides and along the package shelf between the decklid hinges from inside of vehicle.
7. Use piano wire to cut urethane at lower corners. Feed wire under glass at C-pillar through the inside and back out at the package shelf, then around the outside of bead. Use a sawing motion to cut urethane.
8. With aid of a helper, remove window assembly.
INSTALLATION
IMPORTANT: Loose material and/or a rough surface on remaining urethane may cause sealing problems during installation of window assembly.
1. Remove old urethane with a razor knife leaving a thin film (approximately 1-2 mm [0.04 0.08 in.]) around the perimeter of window opening and window assembly (if being reused).
2. Clean the entire window opening and glass bonding surfaces with a clean lint-free, alcohol dampened cloth. Allow to air dry.
3. Install molding around perimeter of glass.
IMPORTANT: If applied molding becomes loose from edge of glass, clear and black prime affected area, allow to air dry. Apply a thin bead of urethane and install molding.
4. Replace molding if damaged or excessively stretched.
NOTE: 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 manufacturer's recommendations for drying time.
5. New window assembly 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.)
6. Apply a smooth continuous bead of adhesive directly to old urethane adhesive in glass opening or to glass. Apply according to dimensions shown.
Bead Dimension
Minimum Width - B: 10 mm (0.39 in.)
Minimum Height - C: 14 mm (0.55 in.)
7. With aid of a helper, lift glass into window opening. Align top edge of molding with notches in roof panel. Make certain the lip of the applied molding laps over the roof feature line.
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.
9. Align glass to upper reveal molding using adjusters at the base of the windshield and center glass side-to-side.
NOTE: Until the new urethane has cured, air pressure from a closing door may cause the window assembly to move. To prevent this, lower one window a minimum of 76 mm (3 in.) before closing the door.
10. Watertest vehicle using soft spray. Use warm or hot water if available. Do not direct 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.
11. Inspect for leaks from inside the vehicle. Paddle in extra adhesive at leak points using a tongue depressor or similar flat flexible tool.
12. Connect rear window defogger electrical connectors to bus bars.
13. Remove previously installed blocks from underneath headliner.
14. Install center high mount stop lamp.
15. Install center high mount stop lamp cover.
IMPORTANT: Vehicle must remain at normal room temperature for 6 hours to complete proper cure of adhesive. Refer to manufacturer's recommendation.