For 1990-2009 cars

### Removal Procedure

#### Tools Required

• | J 24402-A Glass Sealant Remover (Cold Knife)

• | J 39032 Stationary Glass Removal Tool

Caution: When working with any type of glass or sheet metal with exposed or rough edges, wear approved safety glasses and gloves in order to reduce the chance of personal injury.

1. Place protective coverings around the window removal area.
2. Apply masking tape to the painted surfaces around the window in order to prevent damage to the paint.
3. Remove the upper interior quarter trim sail panels. Refer to Sail Panel Replacement in Interior Trim.
4. Disconnect the rear window defogger connectors (1).
5. Open the rear compartment lid.

5.1. | Remove the reveal molding.

5.2. | Starting at the bottom center of the rear window, use pliers in order to pull the reveal molding off of the glass.

5.3. | Cut the molding into 2 pieces.

5.4. | Pull each section of molding from the glass.

5.5. | If necessary, cut the top section of the molding inboard of the upper corners in order to remove the corners of the molding from the glass.

Important: Keep the cutting edge of the tool against the window. This separates the urethane adhesive from the window.

6. Use the J 24402-A and the J 39032 in order to remove the window.
7. With the aid of an assistant, remove the window.
8. The following components may reveal the causes of a broken window:

• | The flange of the window opening

• | The window reveal molding

• | The window

9. Look for any of the following conditions in order to prevent damage to the window:

• | A high weld

• | Solder spots

• | Hardened spot weld sealer

• | Any obstruction or irregularity in the pinchweld flange

10. Inspect the condition of the window opening and the adhesive bead in order to determine which installation method you will use. Refer to Short Method Description or Extended Method Description .

Important: If corrosion of the pinchweld flange is present, or if sheet metal repairs or replacements are necessary, refinish the pinchweld flange in order to present a clean primer only surface. If repairs to the paint are required, mask the flange bonding area prior to the application of the color coat in order to provide a clean primer only surface. Use material such as BASF DE17®, DuPont 2610®, and PPG DP40®.

11. Shake well the pinchweld primer (#3 black).
12. Use a new dauber in order to apply the primer to the primed surface on the flange in the bonding area (1).
13. Allow approximately 10 minutes for drying the primer.

### Installation Procedure

1. With the aid of an assistant, dry fit the window in the opening in order to determine the correct position.
2. Use masking tape in order to mark the location of the window (1) in the opening.
3. Slit the masking tape at the top edge of the window.
4. Remove the window.
5. Place the window on a clean, protected surface.

The inside of the window faces up.

6. If the you reuse the original window, remove all but a thin film of the existing urethane adhesive from the window surface.

Use a utility knife.

7. Clean with GM Glass Cleaner P/N 1050427 or the equivalent the inside surface of the window.
8. If you use the extended installation method, perform the following steps:

| Important: Do not remove all traces of the adhesive. Remove any mounds or loose pieces of the adhesive.

8.1. | Remove all but a thin film of the existing bead of adhesive from the pinchweld flange.

8.2. | Shake well the pinchweld primer (#3 black).

8.3. | Use a new dauber in order to apply the primer to exposed painted surfaces or scratches in the flange in the bonding area.

8.4. | Allow approximately 10 minutes for drying the primer.

Important: Use care when applying the window prep (#1 clear) in order to prevent the window prep from running into the vision area of the window. This primer dries almost instantly. This primer may stain the view area of the window.

9. Using a new dauber, apply window prep (#1 clear) to an area approximately 10-16 mm (3/8-5/8 in) around the entire perimeter of the glass inner surface.
10. Apply window prep (#1 clear) to any exposed edges of the window.
11. Immediately wipe the primed area with a clean cloth.
12. Shake well the window primer (#2 black).
13. Using a new dauber, apply the window primer (#2 black) to the same areas (2) where you applied the window prep (#1 clear).
14. Allow approximately 6 minutes for drying the primer.
15. Prior to application of the urethane adhesive, cut the tip of the applicator nozzle in order to provide the following bead sizes:

• | For the short method, cut the tip in order to provide an adhesive bead of approximately 4.5 mm (1/8-3/16 in).

• | For the extended method, cut the tip in order to provide an adhesive bead of approximately 14 mm (9/16 in).

16. Using a cartridge-type caulking gun, apply a smooth continuous bead of urethane adhesive.
17. When using the short installation method, apply the urethane adhesive to the existing bead of urethane adhesive on the body.
18. When using the extended installation method, use the edge (2) of the window or the inside edge of the reveal molding as a guide for the nozzle.
19. With the aid of an assistant, use rubber suction cups in order to install the window in the opening.
20. Align the tape on the window and on the body.
21. Press firmly the window into place.
22. Tape the window to the body (1) in order to minimize movement.
23. Remove any excess urethane adhesive.

Important: Warm or hot water accelerates the cure of the adhesive. Do not direct a hard stream of high pressure water at the fresh urethane adhesive.

24. Use a soft spray of warm water in order to immediately water test the window.
25. Inspect the window for leaks.
26. If you found any leaks, use a plastic paddle in order to apply extra urethane at the leak point.
27. Complete the following steps in order to properly cure the urethane adhesive:

• | Keep the vehicle at a room temperature of 22°C (72°F) at 30 percent relative humidity.

• | Allow a minimum of 6 hours for the moisture curing urethane adhesive.

• | Allow a minimum of 6 hours for the chemical curing urethane adhesive.

• | Partially lower a door window in order to prevent pressure build-ups when you close doors prior to the urethane adhesive cure.

• | Do not drive the vehicle until the urethane adhesive is cured.

• | Do not use compressed air in order to dry the urethane adhesive.

28. Install the remaining reveal moldings as needed.
29. Connect the rear window electrical connectors.
30. Install the upper interior quarter trim sail panels. Refer to Sail Panel Replacement in Interior Trim.
31. Close the rear compartment lid.