For 1990-2009 cars

### Removal Procedure

#### Tools Required

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

• | J 39032 Stationary Glass Removal Tool

• | Isopropyl alcohol or equivalent

• | Cartridge-type caulking gun

• | Commercial-type utility knife

• | Razor blade scraper

• | Suction cups

• | Plastic Paddle

1. Apply masking tape to the area around the rear door window in order to protect the painted surfaces from damage.
2. Remove the spare tire and wheel assembly from the spare wheel carrier. Refer to Spare Tire Replacement in Tires and Wheels.
3. Gently disengage the plastic retainers which secure the rear door hinge cover (1).
4. Remove the rear door hinge cover (1) from the vehicle.
5. Remove the rear window wiper arm, if equipped. Refer to Rear Window Wiper Arm Replacement in Wiper/Washer Systems.
6. Disconnect the rear window defogger electrical connectors.
7. Remove the rear door window reveal molding.

7.1. | Grasp the lower corner of the rear door window reveal molding by hand and slowly pull the reveal molding away from the rear door window.

7.2. | If the rear door window reveal molding will not release, use a utility knife in order to cut around the rear door window in order to remove the reveal molding.

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: 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.

8. Use the J 24402-A (1) orJ 39032 in order to cut the rear door window (2) from the pinchweld flange.
9. Gently unseat the rear door window retainer-male ends on the window from the rear door window retainer-female ends on the door.
10. With the aid of an assistant, use the suction cups in order to lift the rear door window from the opening.
11. 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

12. 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, the 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.

13. After repairing the open as indicated, perform the following steps:

13.1. | Inspect the condition of the rear window opening and the urethane adhesive bead in order to determine which installation method you will use. Refer to Short Method Description or Extended Method Description for the guidelines.

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

13.3. | 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.

### 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.

After repairing the opening as indicated, perform the following:

1. Shake the pinchweld primer (black #3) for at least one 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 primed (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. If the original reveal molding is damaged it must be replaced, if equipped.

Install a new rear door window reveal molding. Refer to Rear Window Reveal Molding Replacement .

5. With the aid of an assistant, dry fit the rear door 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 door window in the opening.
7. Slit the masking tape at the top edge of the rear door window.
8. With the aid of an assistant and the suction cups, remove the rear door window.
9. Place the rear door window (1) inside up on a clean, protected surface.
10. If the original window is being reused, remove all but approximately 2 mm (3/64 in) of the existing urethane adhesive (2) from the window surface by using a clean utility knife or razor blade scraper.
11. 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 remove all traces of the adhesive. Remove all mounds or loose pieces of urethane adhesive .

12. If the extended method is being used remove all but approximately 2 mm (3/64 in) of the existing bead of adhesive from the pinchweld flange.
13. Shake the pinchweld primer (black #3) for at least one 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.
16. If the extended method is being performed, do the following:

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

17. If installing a new non encapsulated window:

17.1. | Use a new dauber, to apply the rear window prep (clear #3) to the area approximately 10 to 16 mm (3/8 to 5/8 in) around the entire perimeter of the rear window inner surface.

17.2. | Apply rear window prep (clear #1) to the same area of the glass.

17.3. | Wipe the glass primed area immediately with a clean lint free cloth.

17.4. | Shake the glass primer (black #2) for at least one minute.

18. If installing a new encapsulated window:

• | Use a new dauber, in order to apply the window prep (clear #3) to the area approximately 10 to 16 mm (3/8 to 5/8 in) around the entire perimeter of the rear glass inner surface. The glass must be installed within 8 hours after applying the primer to the glass.

• | The primed surface of the glass must be kept clean.

• | Allow the glass primer to dry for approximately 10 minutes.

19. Shake the rear window primer (black #2) for at least one minute.
20. 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.
21. Allow the primer to dry for approximately 10 minutes.
22. If using the short method, cut the tip of the applicator nozzle in order to provide an bead approximately 6.0 mm (1/4 in).
23. If using the extended method, cut the applicator nozzle in order to provide a bead approximately 10.5 mm (0.14 in) wide and 10.5 mm (0.14 in) high.
24. Use a cartridge-type caulking gun, apply a smooth continuous bead of new urethane adhesive around the edge of the rear door window where the primer was applied.
25. When using the short method, apply the urethane adhesive to the existing bead of urethane adhesive on the body.
26. When using the extended method, use the edge of the rear door window or the inside edge of the reveal molding as a guide for the nozzle in order to apply the urethane adhesive to the inner surface of the rear door window.
27. With the aid of an assistant, use the suction cups in order to install the rear door window into the opening.
28. Align the tape on the rear door window and the body.
29. Press the rear door window (2) firmly into place in order to wet-out and seat the urethane adhesive.
30. Tape the rear door window in places to the body in order to minimize movement until the urethane adhesive cures.
31. Clean any excess urethane adhesive from the body.

Important: Do not direct a hard stream of high pressure water at the fresh urethane adhesive.

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

36.1. | 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.

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

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

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

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

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

37. Install the plastic retainers to the rear door hinge cover. Replace with new retainers as needed.
38. Connect the rear window defogger electrical connectors.
39. Install the rear window wiper arm, if equipped. Refer to Rear Window Wiper Arm Replacement in Wiper/Washer Systems.
40. Install the rear door hinge cover to the vehicle. Ensure that the plastic retainers are fully engaged.
41. Install the spare tire and wheel assembly to the spare wheel carrier. Refer to Spare Tire Replacement in Tires and Wheels.
42. Remove the protective coverings and tape from the vehicle.