For 1990-2009 cars

#### Tools Required

• | J-36020 Stationary Glass Removal Tool

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

• | J 24811 Cartridge-type Caulking Gun

• | Urethane Adhesive Kit or Equivalent

• | Isopropyl Alcohol, Prepsol or Equivalent

• | Commercial-type Utility Knife

• | Razor Blade Scraper

• | Suction Cups

### Removal Procedure

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.

Caution: If a window is cracked but still intact, crisscross the window with masking tape in order to reduce the risk of damage or personal injury.

1. Cover the seats and carpeting to protect them from broken glass.
2. Remove the centre pillar lower trim panel. Refer to Center Pillar Lower Trim Panel Replacement.
3. Remove the centre pillar upper trim panel. Refer to Center Pillar Upper Trim Panel Replacement.
4. Remove the rear header trim. Refer to Roof Panel Rear Applique Replacement.
5. Remove the body lock pillar trim. Refer to Body Lock Pillar Applique Replacement.
6. Disconnect the rear window electrical connectors (1), both sides.

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

Important: Use a suitable tool to install the piano wire from J-36020 (2) through the urethane adhesive at an upper corner of the rear window (1).

7. Install J-36020 (2) to the vehicle.
8. Connect the end of the piano wire to the other handle of J-36020 (2).

Important: Keep the inside handle of J-36020 (1) against the rear window (2) and cycle the full length of the piano wire to prevent heat build up.

Important: Care must be taken not to damage the datum pins (4) when cutting through the bead of urethane adhestive around the rear window (2).

Important: The foam spacer across the lower edge of the glass is a single use item and must be replaced.

9. With the aid of an assistant cut through the bead of urethane adhesive around the rear window (2) retaining the rear window (2) to the vehicle (3).

Important: The use of suction cups will aid in the removal of the rear window (1).

10. With the aid of an assistant remove the rear window (1) from the vehicle (2).

### Installation Procedure

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.

Important: Use a lint free cloth and suitable oil free cleaning agent to ensure correct adhesion of the urethane adhesive.

1. Clean the surface and edges of the rear window where the urethane adhesive is to be applied.

Important: The clear glass primer dries almost instantly and may stain the viewing area of the rear window if not applied evenly. Wipe off the clear glass primer with a lint free cloth immediately after application.

Important: Apply the clear glass primer with a suitable applicator.

2. Apply a 50mm wide layer of clear glass primer (1) to the inner surface of the rear window (2) perimeter.

Important: Agitate the black glass primer for 1 minute to mix thoroughly.

Important: Apply a 20mm wide layer of black glass primer with the applicator to the rear window perimeter.

3. Apply a 20mm wide layer of black glass primer (1) to the inner surface of the rear window (2) perimeter.

Caution: Refer to Window Retention Caution in the Preface section.

Important: Apply a 7mm wide and 14mm deep layer of urethane adhesive 20mm inside the perimeter of the rear window.

4. Apply the bead of urethane adhesive (1) to the inner surface of the rear window (2) perimeter.

Important: The rear window (1) is aligned by two datum pins located at the top of the rear window and a foam spacer along the bottom of the rear window (1).

Important: Install a NEW foam spacer along the bottom of the rear window (1).

5. With the aid of an assistant install the rear window (1) to the vehicle (2).
6. Press the rear window (1) firmly into position.

Important: During the curing period of the urethane adhesive, the door windows should be left open to avoid a build up of pressure when the doors are opened and closed.

7. Using suitable tape, secure the rear window in position until the urethane adhesive layer has cured.
8. Connect the rear window electrical connectors (1).
9. Remove the double layer of masking tape from around the perimeter of the painted surfaces and the interior trim.
10. Install the body lock pillar trim. Refer to Body Lock Pillar Applique Replacement.
11. Install the rear header trim. Refer to Roof Panel Rear Applique Replacement.
12. Install the centre pillar upper trim panel. Refer to Center Pillar Upper Trim Panel Replacement.
13. Install the centre pillar lower trim panel. Refer to Center Pillar Lower Trim Panel Replacement.