For 1990-2009 cars

## Quarter Window Replacement Wagon

### Removal Procedure

Caution: Refer to Glass and Sheet Metal Handling Caution in the Preface section.

Notice: Refer to Paint Damage Notice in the Preface section.

Notice: To protect paint from damage, tape quarter panel along/under quarter glass encapsulation using a thick tape.

1. If the quarter glass is to be reused, mark the location using masking tape or a grease pencil with the relationship to the roof outer-drip rail and quarter panel. During installation, the marks can be aligned to guide the glass to the desired position.
2. Remove the rear upper garnish molding.
3. Remove the C-pillar trim.
4. Tape the quarter glass to the body, ensuring the glass is retained as the urethane is being cut.
5. Use a power glass removal tool around the perimeter of the quarter glass, being careful not to damage the finish on the quarter panel.

Caution: Refer to Urethane Smoke Caution in the Preface section.

6. Remove the quarter glass and tape.

### Installation Procedure

Important: Loose urethane and/or a rough surface on the remaining urethane may cause sealing problems during installation of the quarter window.

1. Remove the old urethane with a razor knife leaving a thin film, approximately 1-2 mm (0.04-0.08 in) around the perimeter of the window opening and old quarter glass, if being reused.
2. Install the C-pillar trim.
3. Clean the entire window opening and glass bonding surfaces with a clean, lint-free, alcohol-dampened cloth. Allow to air day.

Notice: To prevent corrosion, paint damage around the window opening by the power glass removal tool must be covered with pinchweld primer. Do not prime over existing urethane. Follow manufacturers recommendations for drying time.

Important: Shake the glass prep primer (Clear #1) well before using.

4. For new quarter glass only, apply the glass prep primer (Clear #1) around the entire perimeter of the glass using a dauber. Wipe dry with a clean, lint-free cloth.

Specification
The primer area minimum width (A) is 18 mm (0.71 in).

Important: Shake the glass primer (Black #2) well before applying.

5. With a new dauber, apply the glass prep primer (Black #2) around the entire perimeter over Clear #1. Allow the primer to dry 5 minutes before applying the urethane.

Specification
The primer area minimum width (A) is 18 mm (0.71 in).

6. Apply a smooth continuous bead of adhesive directly to the old urethane adhesive in the glass opening or to the glass. Apply according to the dimensions shown.

Specification

• | The bead dimension for the minimum width (B) is 8 mm (0.32 in).

• | The bead dimension for the minimum height (C) is 14 mm (0.55 in).

7. Place the glass into the window opening. If reusing the old quarter glass, align to the previously marked position.

Notice: Refer to Air Pressure Moving Glass Notice in the Preface section.

8. Press the glass firmly to wet-out and set the adhesive. Use care to avoid excessive squeeze-out which would cause an appearance problem. Using duct tape, or an equivalent, tape the glass to the roof.
9. Watertest the vehicle using a soft spray. Use warm or hot water if available. Do not direct a hard stream of water at the fresh adhesive material. Water applied on top of the urethane adhesive, during a watertest or as a separate operation, will speed up the cure of the urethane.
10. Inspect for leaks from inside the vehicle. Paddle in extra adhesive at the leak points using a tongue depressor or similar flat flexible tool.
11. Install the rear upper garnish molding.
12. The vehicle must remain at normal room temperature for 6 hours to complete proper cure of the adhesive. Refer to the manufacturer's recommendations.

## Quarter Window Replacement Sedan

### Removal Procedure

1. Lower the rear seat back.
2. Remove the C-pillar trim.
3. Mark the quarter glass and body with a grease pencil to assist in the alignment upon installation.
4. Remove the retaining nuts from the quarter glass.
5. Remove the quarter glass.
6. Remove the sealing caulk from the glass surface.

### Installation Procedure

1. Install the sealing caulk around the perimeter of the glass.
2. Position the quarter glass in the opening. If using the old quarter glass, align to the previously marked position.

Notice: Refer to Fastener Notice in the Preface section.

3. Install the nuts to the quarter glass.

Tighten
Tighten the quarter glass nuts (Sedan) to 2 N·m (18 lb in).

4. Install the C-pillar trim.
5. Watertest the vehicle using a soft spray.
6. Inspect for leaks from inside the vehicle.