Rear Window Assembly
REAR WINDOW ASSEMBLY - SEDANREMOVAL
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.
IMPORTANT: Both body lock pillar upper moldings must be removed.
1. Remove rear window trim finish panel.
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, rear window defogger. Locate electrical connectors so as not to damage wiring/connectors when using urethane power removal tool.
6. Remove roof side outer rear panel.
7. Remove quarter panel fasteners at lock pillar 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.
8. 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.
NOTE: Care must be taken not to damage the roof panel when using power glass removal tool.
9. Use piano wire to cut urethane at lower comers. 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.
10. 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) around the perimeter of window opening and window assembly (if being reused).
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.
2. 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 edge of glass, clear and black prime affected area, allow to air dry. Apply a thin bead of urethane and install molding.
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.
3. Tape decklid in half open position to provide clearance for installing glass.
4. 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.)
5. The urethane adhesive bead may be applied to either the space frame (pinchweld flange) or back glass.
5.1 Pinchweld flange method. Verify location of bead and apply a smooth continuous bead of urethane adhesive around the window opening.
5.2 Window assembly method. Apply a smooth continuous bead of urethane adhesive around perimeter of glass. Apply urethane up to the edge of applied molding.
Bead Dimension
Minimum Width - B: 10 mm (0.39 in.)
Minimum Height - C: 14 mm (0.55 in.)
6. 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.
7. Press glass firmly to wet-out and set adhesive. Use care to avoid excessive squeeze out which would cause an appearance problem.
8. Slide adjustment arm on anti-slide clip upward and use tape from back glass to roof to hold back glass in position until urethane adhesive has cured.
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.
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 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,
10. Inspect for leaks from inside the vehicle. Paddle in extra adhesive at leak points using a tongue depressor or similar flat flexible tool.
11. Install quarter panel fasteners.
Torque:
Quarter Panel Fasteners: 9 N.m (80 in.lbs)
12. Install roof side outer rear panel.
13. Connect electrical connectors to bus bar.
14. Install headliner.
15. Install center high mount stop lamp.
16. Install center high mount stop lamp cover.
17. Install rear window trim finish panel.