Stationary Quarter Window Replacement
QUARTER WINDOW 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 C-Pillar applique.
2. Remove B-D Pillar applique
3. Remove tail light assembly.
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/MHSA 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.
IMPORTANT: The quarter window has hard plastic alignment pins located at the forward-top and rear-bottom corners. These alignment pins will require higher cutting effort.
4. Cut urethane from quarter window.
x = Piano Wire
O = Cold Knife
4.1 Using piano wire and handles cut the urethane from the sides, top and corners of the quarter window. A soapy water solution may be sprayed along the urethane bead to ease the cutting process.
4.2 Using a cold knife, cut the urethane from the bottom of the quarter window.
5. Remove quarter window.
INSTALLATION
NOTE:
- To avoid scratching the quarter window or blackout on quarter window outer edge, care must be taken when removing urethane with razor blade.
- Loose material and/or a rough surface on remaining urethane may cause sealing problems during installation.
1. Remove old urethane with a new razor knife, leaving a thin film (approximately 1-2 mm [0.044).08 in.]) around the perimeter of quarter window opening. Any gaps in urethane film must be primed using glass prep primer (Clean #1) and glass primer (Black #2).
2. Clean the entire quarter 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 window opening by the glass removal tool must be covered with pinch weld primer. Do not prime over existing urethane. Follow manufacturer's recommendation for drying time.
- To avoid scratching the quarter window or blackout on quarter window outer edge, care must be taken when removing urethane with razor blade.
- Loose material and/or a rough surface on remaining urethane may cause sealing problems during installation.
3. Preparation for window installation.
3.1 Shake glass prep primer (Clear #1) or equivalent well before applying. Apply glass prep primer (Clear #1) or equivalent around the entire perimeter of the glass using a dauber.
3.2 Wipe area dry with a clean lint-free cloth.
4. Prime quarter window.
4.1 Shake glass primer (Black #2) or equivalent well before applying.
4.2 With a new dauber apply glass primer (Black #2) or equivalent to the entire perimeter over glass prep primer (Clear #1) or equivalent.
4.3 Allow glass primer to dry 5 minutes betore applying urethane.
5. Apply a smooth and continuous bead of adhesive directly to old urethane or to the primered surface of glass.
5.1 Start bead at bottom of the quarter window to prevent leaks.
5.2 Apply according to the following dimensions shown in illustration.
1. Minimum Height: 7 mm (0.27 in.)
2. Minimum Width: 12 mm (0.47 in.)
NOTE: Until the urethane has cured, air pressure from a closing door may cause the quarter window to move. To prevent this from occurring, lower one of the rear door windows a minimum of 76 mm (3 in.) before closing door.
6. Place the quarter window into position by fitting alignment pins into alignment holes in the spaceframe.
7. Press glass firmly to wet-out and set adhesive. Use care to avoid excessive squeeze out which would cause an appearance problem.
8. Apply tape to hold quarter window in position until urethane is cured.
9. Water test 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 water test or part of a separate operation, wHI speed up the cure of the urethane.
10. Inspect for leaks from inside the vehicle. Paddle in extra adhesive at leak points using tongue depressor or similar flat flexible tool.
11. Install tail light assembly.
Torque:
Tail Light Assembly Bolts: 2.5 N.m (22 in-lbs)
12. Install E-D Pillar applique.
Torque:
B-D Pillar Applique Fasteners: 2 N.m (18 in-lbs)
13. Install C-Pillar applique.
Torque:
C-Pillar Applique Fasteners: 2 N.m (18 in-lbs)