For 1990-2009 cars

#### Tools Required

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

• | J 39032 Stationary Glass Removal Tool

• | Urethane Adhesive Kit GM P/N 12346392 or equivalent

• | Isopropyl Alcohol or Equivalent

• | Cartridge-type Caulking Gun

• | Commercial-type Utility Knife

• | Razor Blade Scraper

• | Suction Cups

• | Plastic Paddle

### Removal Procedure

Important: Before cutting out a stationary window, apply a double layer of masking tape around the perimeter of the painted surfaces and inner trim of the window.

1. Disconnect the rear window defogger electrical connector from the rear window defogger, if equipped.
2. Gently pry and remove the quarter upper trim panels (2) from the vehicle.

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.

Important: The rear window reveal molding fills the cavities between the body and rear window and can not be reused if stretched or damaged.

3. Remove the rear window reveal molding.
4. Grasp the upper corner of the rear window reveal molding by hand and slowly pull the reveal molding away from the rear window.
5. If the rear window reveal molding will not release, use a utility knife in order to cut around the rear window in order to remove the rear window reveal molding.

Important: Keep the cutting edge of the tool against the rear window when removing the rear window. This will allow the urethane adhesive to be separated from the rear window. Leave a base of urethane on the pinchweld flange. The only suitable lubrication is clear water.

6. Use the J 24402-A or J 39032 in order to remove the rear window.
7. With the aid of an assistant, use the suction cups in order to lift the rear window from the opening.

### Installation Procedure

Caution: When replacing stationary windows, use Urethane Adhesive Kit GM P/N 12346392 (Canadian P/N 10952983), or a urethane adhesive system meeting GM Specification GM3651G, to maintain original installation integrity. Failure to use the urethane adhesive kit will result in poor retention of the window which may allow unrestrained occupants to be ejected from the vehicle resulting in personal injury.

1. Inspect the following components for the causes of a broken rear window:

• | The flange of the rear window opening

• | The rear window reveal molding

• | The rear window

2. Inspect for any of the following problems in order to help prevent future breakage of the rear window:

• | High weld

• | Solder spots

• | Hardened spot weld sealer

• | Any other obstruction or irregularity in the pinchweld flange

Important: If corrosion of the pinchweld flange is present, or if sheet metal repairs or replacements are required, refinish the pinchweld flange in order to present a clean primer only surface. If paint repairs are required, mask the flange bonding area prior to the application of the color coat in order to provide a clean primer only surface. Materials such as BASF DE17®, DuPont 2610®, Sherwin-Williams PSE 4600 and NP70® and Martin-Semour 5120 and 5130® products are approved for this application.

3. After repairing the opening as indicated, perform the following steps:

• | Inspect the condition of the rear window opening and the adhesive bead to determine which installation method should be used. Refer to Short Method Description or Extended Method Description for guidelines.

• | Remove all traces of broken glass from the vehicle.

• | Clean around the edge of the inside surface of the rear window with a 50/50 mixture of isopropyl alcohol and water by volume on a dampened lint free cloth.

After repairing the opening as indicated, perform the following:

1. Shake the pinchweld primer (black #3) for at least 1 minute.

Caution: Failure to prep the area prior to the application of primer may cause insufficient bonding of urethane adhesive. Insufficient bonding of urethane adhesive may allow unrestrained occupants to be ejected from the vehicle resulting in personal injury.

2. Use a new dauber to apply the pinchweld primer (1) (black #3) to the surface of the bonding area.
3. Allow the primer to dry for approximately 10 minutes. Ensure that all nicks and scratches are covered.
4. Install the rear window reveal molding. If the original reveal molding is damaged, it must be replaced. Refer to Rear Window Reveal Molding Replacement .
5. With the aid of an assistant, dry fit the rear window in the opening in order to determine the correct way to position the window in the opening.
6. Use masking tape in order to mark the location of the rear window in the opening.
7. Slit the masking tape at the top edge of the rear window.
8. With the aid of an assistant and the suction cups, remove the rear window.
9. Place the rear window inside up on a clean, protected surface.
10. If the original window (2) is being reused, remove all but a thin film of the existing urethane adhesive (3) from the window surface by using a clean utility knife or a razor blade scraper.

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

11. If the extended method is being used remove all but approximately 2 mm (3/64 in) of the existing bead of adhesive (2) from the pinchweld flange.
12. Clean around the edge of the inside surface of the window with a 50/50 mixture of isopropyl alcohol and water by volume on a dampened lint free cloth.

Important: Do not apply the (black #3) primer to the existing bead of the urethane adhesive. Apply the primer only to nicks, scratches or the primed surfaces.

13. Shake the pinchweld primer (black #3) for at least 1 minute.
14. Use a new dauber to apply the primer to the surface of the pinchweld flange.
15. Allow the pinchweld primer to dry for approximately 10 minutes.

Important: Use care when applying the glass prep (clear #1) to the rear window. This primer dries almost instantly and may stain the viewing area of the rear window if not applied evenly.

16. Use a new dauber, to apply the glass prep (clear #1) to the area approximately 10-16 mm (3/8-5/8 in) around the entire perimeter of the window inner surface.
17. Apply a second coat of the glass prep number (clear #1) to the same area of the glass.
18. Wipe the glass primed area immediately with a clean lint free cloth.
19. Shake the glass primer (black #2) for at least 1 minute.
20. Shake the rear window primer (black #2) for at least 1 minute.
21. Use a new dauber, in order to apply the rear window primer (black #2) to the areas of the rear window (1) to which prep (clear #1) was applied.

The glass primer (black #2) is good up to 8 hours after applying it to the glass. The primed surface of the glass must be kept clean.

22. Allow the primer to dry for approximately 10 minutes.
23. If using the short method, cut the tip of the applicator nozzle in order to provide a bead approximately 6.0 mm (1/4 in).
24. If using the extended method, cut the applicator nozzle in order to provide a bead approximately 12.7 mm (0.5 in) wide and 12.7 mm (0.5 in) high.
25. Use a cartridge-type caulking gun to apply a smooth, continuous bead of urethane adhesive.
26. When using the short method, apply the urethane adhesive to the existing bead of urethane adhesive on the body.
27. When using the extended method, use the edge of the rear window (3) or the inside edge of the reveal molding as a guide for the nozzle in order to apply the urethane adhesive (1) to the inner surface of the rear window.
28. With the aid of an assistant, use the suction cups in order to install the rear window into the opening.
29. Align the tape lines on the rear window and the body.
30. Press the rear window firmly into place.
31. Tape the rear window to the body in order to minimize movement until the urethane adhesive cures.
32. Clean any excess urethane adhesive from the body.

Important: Do not direct a hard stream of high pressure water to the freshly applied urethane adhesive.

33. Use a soft spray of warm water in order to immediately watertest the rear window.
34. Inspect the rear window for leaks.
35. If any leaks are found, use a plastic paddle in order to apply extra urethane at the leak point.
36. Retest the rear window for leaks.
37. The following conditions must be maintained to properly cure the urethane.

37.1. | Allow the vehicle to remain at room temperature 21°C (70°F) at 30 percent relative humidity.

| Caution: At least 24 hours are required for complete curing of repair material. The repair area should not be physically distrubed until after that time. Insufficient curing of urethane adhesive may allow unrestrained occupants to be ejected from the vehicle resulting in personal injury.

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

37.3. | Allow a minimum of 1 hour to 1 1/2 hours for the chemical curing urethane adhesive.

37.4. | Partially lower a rear door window in order to prevent pressure buildups when closing doors before the urethane adhesive cures.

37.5. | Do not drive the vehicle until the urethane adhesive is fully cured. Refer to the above curing times.

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

38. Install the upper rear quarter trim panels to the vehicle.
39. Connect the rear window defogger electrical connector to the rear window defogger, if equipped.
40. Remove the protective coverings and tape from the vehicle.