For 1990-2009 cars

## Quarter Window Replacement Coupe

### Removal Procedure

Caution: Always wear heavy gloves and safety glasses when handling glass to minimize the risk of injury.

Notice: Place protective covers on body to prevent paint damage.

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 relationship to roof outer drip rail and the quarter panel. During installation, marks can be aligned to guide the glass to the desired position.
2. Remove the roof outer drip rail. Refer to Roof Front Drip Molding Replacement - Left Side and Roof Front Drip Molding Replacement - Right Side in Roof.
3. Remove the quarter window upper garnish molding from the right side only. Refer to Garnish Molding Replacement - Quarter Window Upper in Interior Trim.
4. Partially remove the quarter lower trim panel.

Notice: Failure to use tongue depressors or equivalent could result in the piano wire damaging encapsulation.

5. Use two 154 mm (6 in) tongue depressors, or equivalent, and place under B-pillar encapsulation.
6. Feed piano wire around the perimeter of the quarter glass being careful not to damage the finish on the quarter panel.
7. Tape the quarter glass to the body to retain the glass as the urethane is being cut.

Caution: When using power tools that may create smoke when cutting urethane sealant, work should be done in a well ventilated area and/or with a NIOSH/MSHA Approved air supplied respirator to prevent possible harmful exposure.

When the urethane adhesive is heated enough to give off smoke, high levels of methylene diisocyanate (MDI) may be present. Unprotected exposure to methylene diisocyanate (MDI) may result in severe, chronic, debilitating respiratory problems.
8. Use a sawing motion to cut through the urethane.
9. Remove the quarter glass and tape.
10. 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 window opening and old quarter glass, if being reused.

### Installation Procedure

Notice: Loose urethane and/or rough surfaces may cause sealing problems during installation. For cars with a sunroof, it is important to install the fasteners to the new roof assembly before the roof is installed in place.

1. Install the roof outer drip rail screws in order according to illustration.

Notice: Refer to Title not found in the Preface section.

2. Install the quarter lower trim panel.

Tighten
Tighten the lower quarter trim panel fastener to 1.5 N·m (13 lb in).

3. Clean the entire window opening and glass bonding surfaces with a clean, lint free, alcohol dampened cloth. Allow to air dry.

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.

4. Quarter glass installation:

4.1. | Shake glass prep primer, Clear #1 or equivalent, well before using.

4.2. | Apply glass prep primer, Clear #1 or equivalent, around the entire perimeter of the glass using a dauber.

4.3. | Wipe dry with a clean lint-free cloth.

| Important: Primer area has a minimum width diameter of 18 mm (0.71 in) in area (A) area.

4.4. | Shake glass primer, Black #2 or equivalent, well before applying.

4.5. | With a new dauber, apply glass prep primer Black #2 or equivalent, around the entire perimeter over Clear #1 or equivalent.

4.6. | Allow primer to dry 5 minutes before applying urethane.

5. Apply a smooth continuous bead of adhesive directly to old urethane adhesive in glass opening or to glass. Apply according to dimensions shown. Start and stop application of urethane at bottom of windshield.

Bead Dimension

• | Minimum Width: Dimension (B) 8 mm (0.32 in).

• | Minimum Height: Dimension (C) 16 mm (0.64 in).

6. Place the quarter glass into the window opening.

• | If reusing the old quarter glass, align to the previously marked position.

• | For new quarter glass, align the locating pins to the holes in the window opening.

Notice: Until the new urethane has cured, air pressure from a closing door may cause the glass to move. To prevent this, lower the opposite side door window a minimum of 76 mm (3 in) before closing the door.

Important: The vehicle must remain at normal room temperature for 6 hours to complete proper cure of the adhesive. Refer to the manufacturer's recommendation.

7. Press glass firmly to wet-out and set adhesive. Use care to avoid excessive squeeze out which would cause an appearance problem. Using duct tape or equivalent , tape glass up to roof.
8. Watertest the vehicle at once using soft spray. Use warm or hot water if available. Do not direct hard stream of water at fresh adhesive material. Water applied on top of urethane adhesive, during watertest or as a separate operation, will speed up the cure of the urethane.
9. Inspect for leaks from inside the car. Paddle in extra adhesive at leak points using a tongue depressor or similar flat flexible tool.
10. Install the quarter window upper garnish molding, right side only.

## Quarter Window Replacement Wagon

### Removal Procedure

1. Lower the rear seat back.
2. Remove the molding assembly shock tower.
3. Remove the body seal at the lock pillar.
4. Partially remove the top portion of the lower lock pillar molding.
5. Open the liftgate and remove the headlining trim finish panel.
6. Remove the rear end trim finish panel.
7. Remove the body rear corner trim panel.
8. Partially remove the body lock pillar upper panel.
9. Partially remove the wheelhouse trim finish panel.
10. If the quarter window is to be reused, mark the location using masking tape or a grease pencil with the relationship to the roof side outer rear panel.
11. Remove the panel -- rear side door frame rear.
12. Remove the panel -- back body outer rear.
13. Remove the roof side outer rear panel.

Caution: When using power tools that may create smoke when cutting urethane sealant, work should be done in a well ventilated area and/or with a NIOSH/MSHA Approved air supplied respirator to prevent possible harmful exposure.

When the urethane adhesive is heated enough to give off smoke, high levels of methylene diisocyanate (MDI) may be present. Unprotected exposure to methylene diisocyanate (MDI) may result in severe, chronic, debilitating respiratory problems.
14. Feed piano wire around the perimeter of the quarter window being careful not to damage the finish on the quarter panel.
15. Tape the quarter window to the body to retain the glass as the urethane is being cut.
16. Use a sawing motion to cut through the urethane.
17. Remove the quarter window and tape.

### Installation Procedure

Notice: Until the new urethane has cured, air pressure from a closing door may cause the glass to move. To prevent this, lower the opposite side door window a minimum of 76 mm (3 in) before closing the door.

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 window, if being reused.
2. Clean the entire window opening and glass bonding surfaces with a clean lint-free, alcohol dampened cloth. Allow to air dry.

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.

Notice: To avoid damage to the outer edge of the glass, be careful not to scratch the glass when removing urethane with a razor blade.

Notice: Loose urethane and/or rough surfaces may cause sealing problems during installation. For cars with a sunroof, it is important to install the fasteners to the new roof assembly before the roof is installed in place.

Important: Apply pinchweld primer to all scratches and bare metal on pinchweld. Do not prime over any existing urethane. Follow manufacturer's recommendations for drying time.

3. Preparation for window installation:

• | If the existing quarter window will be used:

- | Clean the old urethane from the quarter window using a new razor knife. Leave a thin film, approximately 1-2 mm (0.04-0.08 in) around the perimeter of the quarter window.

- | Clean the area with urethane with a quality grade of rubbing alcohol using a clean, lint-free cloth. Wipe dry with a clean, lint-free cloth, and allow to dry so there is no trace of rubbing alcohol on the quarter window or the urethane.

| Important: Primer area has a minimum width diameter of 18 mm (0.71 in) in area (A) area.

• | If a new quarter window will be used:

- | Shake the glass prep primer, Clear #1 or equivalent, well before applying. Apply glass prep primer, Clear #1 or equivalent, around the entire perimeter of glass using a dauber.

- | Wipe dry with a clean, lint-free cloth.

4. Prime the window opening area.

4.1. | Shake the glass primer, Black #2 or equivalent, well before applying.

| Important: Primer area has a minimum width diameter of 18 mm (0.71 in) in area (A) area.

| Important: Use the line along top of the quarter window below the quarter window upper molding as a guide when applying primer.

4.2. | With a new dauber, apply the glass prep primer, Black #2 or equivalent, around the entire perimeter over Clear #1 or equivalent.

4.3. | Allow primer to dry 5 minutes before applying the urethane.

5. Install the roof side outer rear panel.
6. Install the panel -- rear side door frame rear.
7. 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 following dimensions:

Bead Dimensions

• | Minimum Width: Dimension (B) 16 mm (0.51 in).

• | Minimum Height: Dimension (C) 8 mm (0.32 in).

8. Position the quarter window in the opening.

• | If using the old quarter window, align to the previously marked position.

• | If using new quarter window, align the locating pins to the holes in window opening.

Notice: Until the new urethane has cured, air pressure from a closing door may cause the glass to move. To prevent this, lower the opposite side door window a minimum of 76 mm (3 in) before closing the door.

Important: The vehicle must remain at normal room temperature for 6 hours to complete proper cure of adhesive. Refer to manufacturer's recommendation.

9. Press the glass firmly to wet-out and set the adhesive. Use tape from the upper applique and quarter panel to hold in position until the urethane adhesive is cured.
10. Watertest the vehicle at once using soft spray. Use warm or hot water if available. Do not direct a hard stream of water at fresh adhesive. Water applied on top of the urethane adhesive, during watertest or as a separate operation, will speed up the cure of the urethane.
11. Inspect for leaks from inside the car. Paddle in extra adhesive at leak points using a tongue depressor or similar flat flexible tool.
12. Install the panel -- back body outer rear.

Important: For the driver's side only, connect the radio antenna wire.

13. Install the wheelhouse trim finish panel.
14. Install the upper panel -- body lock pillar.
15. Install the body rear corner trim panel.
16. Install the rear end trim -- finish penal molding.
17. Install the headlining trim finish panel.
18. Install the lower lock pillar molding.
19. Install the body seal at lock pillar.
20. Install the molding assembly shock tower.
21. Raise the rear seat back.