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. Remove the rear wiper arm, if equipped. Refer to Wiper Arm Replacement - Rear in Wipers/Washer Systems.
2. Remove the high-mounted stoplamp. Refer to High Mounted Stoplamp Replacement (2 Door) in Lighting Systems.
3. Remove the inner liftgate weatherstrip by pulling the weatherstrip from the pinch weld flange.
4. Disconnect the electrical connector from the rear window defogger on the liftgate window.
5. Apply masking tape to the area around the liftgate window in order to protect the painted surfaces from damage.

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.

6. Cut the molding with a utility knife in order to remove the reveal molding from the top and from the sides of the liftgate window.

Important: Keep the sharp edge of the tool (2) against the liftgate window (1) when removing the liftgate window. This will allow the urethane adhesive to be separated from the liftgate window (1). Leave a base of urethane on the pinchweld flange. The only suitable lubrication is clear water.

7. Use the J 24402-A (2) or J 39032 in order to cut the liftgate window (1) from the pinchweld flange. Do this from inside the vehicle in order to protect the outer paint surface.
8. Remove the liftgate window (1) from the vehicle with aid of an assistant and suction cups.
9. Remove the liftgate reveal molding from the edge of the window.
10. Inspect the following components for the causes of a broken liftgate window:

• | The flange of the liftgate window opening

• | The liftgate window reveal molding

• | The liftgate window

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

• | High weld

• | Solder spots

• | Hardened spot weld sealer

• | Any 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 necessary, 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 NP 70 and Martin-Semour 5120 and 5130 products are approved for this application.

12. After repairing the opening, perform the following steps:

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

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

12.3. | Clean around the edge of the inside surface of the liftgate 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, perform the following steps:

1. Shake well the #3 black pinchweld primer coating .

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. Using a new dauber, apply the #3 black primer coating to the primed surface of the flange in the bond area.
3. Allow the primer coating to dry for approximately 10 minutes. Ensure that all nicks and scratches are covered.
4. Install a new liftgate window reveal molding to the edge of the window.
5. With the aid of an assistant, dry fit the liftgate window in the opening in order to determine the correct way to position the liftgate window in the opening. Verify that the clearances (1,2) are equal.
6. Use the masking tape in order to mark the location of the liftgate window in the opening.
7. Slit the masking tape at the top edge and at the sides of the liftgate window.
8. Remove the liftgate window from the opening with the aid of an assistant and suction cups.
9. Place the liftgate window with the inside up, on a surface that is clean and is secure.
10. If you reuse the original liftgate window (2), remove almost all but approximately 2 mm (3/64 in) of the existing urethane adhesive (3) from the liftgate window surface, using a utility knife or razor blade scraper.
11. Clean the inside surface of the liftgate window (2) 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 existing bead of urethane adhesive (2) except approximately 2 mm (3/64 in), from the pinchweld flange.
13. Shake well, the #3 black pinchweld primer coating.
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.

Important: Use care when applying the #1 clear window preparation in order to prevent the liftgate window preparation from running into the vision area of the liftgate window. This primer coating dries almost immediately and may cause discoloration in the vision area of the windshield if not applied evenly.

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

Apply a second coat of the glass prep number (clear #1) to the same area of the glass.

17. Wipe the primed area immediately with a clean lint free cloth.
18. Shake well, the #2 black pinchweld primer coating.
19. Using a new dauber, apply the #2 black window primer coating over the #1 clear window preparation.
20. The #2 black window primer coating is good up to 8 hours after applying it to the glass. The primed surface of the glass must be kept clean.
21. Allow the primer coating to dry for approximately 10 minutes.
22. If using the short method, cut the tip of the nozzle to provide an adhesive bead of 6.0 mm (1/4 in).
23. If using the extended method, cut the tip 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 caulking gun, in order to apply a smooth continuous bead of urethane adhesive.
25. If reusing the original glass apply the new urethane adhesive on the top of the fresh trimmed urethane adhesive.
26. When using the extended method, apply a bead of urethane adhesive that is smooth and continuous, around the edge of the liftgate window where the primer coating was applied.
27. Use suction cups, with the aid of a assistant, in order to install the liftgate window (3) into the opening.
28. Align the tape lines on the liftgate window and on the body.
29. Press the liftgate window firmly into position.
30. Tape the liftgate window to the body in order to minimize movement until the urethane adhesive cures.
31. Clean any excess urethane from the body.

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

32. Use a gentle spray in order to water-test the liftgate window immediately.

Warm water or hot water is preferred in order to accelerate the cure of the adhesive.

33. Inspect the liftgate window for leaks:

If you locate leaks, use a plastic paddle in order to apply extra urethane adhesive at the leak point.

34. Retest the liftgate window for leaks.
35. 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 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 cure 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.

36. Connect the electrical connector from the rear window defogger on the liftgate window.
37. Install the inner liftgate weather strip to the pinch weld flange.
38. Install the high-mounted stoplamp. Refer to High Mount Stop Lamp Replacement in Lighting Systems.
39. Install the rear wiper arm, if equipped. Refer to Rear Window Wiper Arm Replacement in Wiper/Washer Systems.
40. Remove the protective coverings and tape from the vehicle liftgate.