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 window in order to protect the painted surfaces from damage.
2. Disconnect the rear defogger electrical connector from the rear-window defogger, if equipped.
3. Perform the following steps in order to remove the bottom rear window molding:

3.1. | Open the rear compartment lid.

3.2. | Remove the 7 screws.

3.3. | Remove the 2 end moldings.

3.4. | Remove the bottom rear window molding from the vehicle.

4. Remove the roof drip-rail moldings. Refer to Body Side Roof Drip Molding Replacement in Exterior Trim.
5. Remove the rear window reveal molding.

5.1. | Grasp the upper corner of the rear window reveal molding, and slowly pull the reveal molding away from the rear window.

5.2. | 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.

6. Remove the following components from the bottom of each side of the rear window:

6.1. | The screw

6.2. | The rear window stopper (2)

7. Gently loosen the upper rear quarter trim panels and remove the panels.
8. Using a sharp utility knife, make a preliminary cut around the perimeter of the rear window, cut as close to edge of the rear window as possible.

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.

9. Use the J 24402-A (1) or J 39032 in order to cut the rear window from the pinchweld flange.
10. When cutting the urethane, apply a spray mist of water around the surface to aid in the removal. Keep the blade on the knife as close to the pinchweld flange as possible in order to leave a base of urethane on the glass.
11. The rear window reveal molding retains the urethane in the cavity between the body and the opening. If the rear window reveal molding is damaged by cutting the molding too close to the rear window surface, replace the molding.
12. With the aid of an assistant, use the suction cups in order to lift the rear window from the opening.
13. 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

14. 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

• | An other obstruction or an 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.

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

15.1. | 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.

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

15.3. | 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 #3 black window primer coating well.

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 in order to apply the primer coating to the surface of the bonding area.
3. Allow the primer coating 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 the new rear window reveal molding to the rear window.

5. With the aid of an assistant, fit the dry rear window into the opening in order to determine the correct way to position the rear window in the opening.
6. Use the masking tape (1) in order to mark the location of the rear window in the opening.
7. Slit the masking tape (1) at the top edge of the rear window.
8. With the aid of an assistant, use suction cups in order to remove the rear window from the opening.
9. Place the rear window on a clean, and secure surface with the inside of the rear window turned up.
10. If the original window (2) is being reused, remove all but approximately 2 mm (3/64 in) of the existing urethane adhesive from the window surface by using a utility knife or a 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: You do not need to remove all of the adhesive, but remove all of the large pieces or all of the loose pieces.

12. If the extended method is being used remove all of the adhesive but approximately 2 mm (3/64 in) of the existing bead of adhesive (2) from the pinchweld flange.
13. Shake the #3 black window primer coating well.
14. Use a new dauber in order to apply the primer coating to the surface of the pinchweld flange.
15. Allow the primer coating to dry for approximately 10 minutes.
16. If the extended method is being performed, do the following:

Important: Use care when applying the #1 clear window preparation in order to prevent the rear window preparation from running into the vision area of the rear window. This primer coating dries almost immediately and may cause discoloration in the vision area of the windshield.

17. If installing a new non encapsulated rear window perform the following actions:

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

17.2. | Apply the #1 clear window preparation to the same area of the glass.

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

17.4. | Shake the #2 black window primer coating well.

18. If you install a new encapsulated window:

• | Use a new dauber in order to apply the #3 clear window preparation to the area approximately 10 to 16 mm (3/8 to 5/8 in) around the entire perimeter of the 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 #2 black window primer coating well.
20. Using a new dauber, apply the #2 black window primer coating (2) to the same areas that the #1 clear, window preparation was applied.
21. Allow the primer coating to dry for approximately 10 minutes.
22. If using the short method, cut the tip of the applicator nozzle in order to provide an adhesive bead of approximately 6.0 mm (0.25 in).
23. If using the extended method, cut the tip of the applicator nozzle in order to provide an adhesive bead of approximately 10.5 mm (0.14 in) wide and 10.5 mm (0.14 in) high.
24. Use a cartridge-type caulking gun, in order to apply a smooth continuous bead of urethane adhesive around the edge of the rear 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, apply a smooth continuous bead of urethane adhesive (2) around the edge of the rear window (1) or the inside edge of the reveal molding where the primer coating was applied.
27. With the aid of suction cups and an assistant, install the rear window into the opening.
28. Align the tape lines (1) on the rear window and on the body pillar.
29. Verify that the top of the rear window is seated approximately 3.5 mm (0.138 in) from the roof panel.
30. Press the rear window firmly into position in order to wet-out and seat the urethane adhesive.
31. Install the lower stopper of the rear window (2) to the bottom of each side of the rear window. Secure each stopper with 1 screw.
32. Tape the rear window to the body in order to minimize movement until the urethane adhesive cures.
33. Clean up any excess urethane from the body.

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

34. Use a gentle spray in order to immediately water-test the rear window.
35. Inspect the rear window for leaks.
36. If you detect leaks, use a plastic paddle in order to apply extra urethane adhesive at the leak point.
37. Retest the rear window for leaks.
38. In order to correctly cure the urethane, observe the following rules:

• | Allow the vehicle to remain at room temperature of 21°C (70°F) at 30 percent or less 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.

• | Allow the moisture curing urethane adhesive to cure for at least 6 hours.

• | Allow the chemical curing urethane adhesive to dry for at least 1 to 1 1/2 hours.

• | Partially lower a door window in order to prevent pressure buildups when closing doors prior to urethane adhesive cure.

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

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

Important: Verify that the adhesive is set and that the window is secure before continuing with the following steps.

39. Perform the following steps in order to install the bottom rear window molding:

39.1. | Open the rear compartment lid.

39.2. | Install the 2 end moldings.

39.3. | Install the bottom rear window molding to the vehicle.

39.4. | Install the 7 screws.

40. Install the upper rear quarter trim panels to the vehicle.
41. Connect the rear defogger electrical connector to the rear-window defogger, if equipped.
42. Install the roof drip-rail moldings. Refer to Body Side Roof Drip Molding Replacement in Exterior Trim.
43. Remove the protective coverings and tape from the vehicle.