For 1990-2009 cars

## Rear Window Replacement Sedan

### 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.

Important: Both body lock pillar upper moldings must be removed.

1. Remove the rear window trim finish panel. Refer to Upper Rear Trim Finish Panel Replacement in Interior Trim.
2. Remove the center high-mount stop lamp cover.
3. Remove the fasteners from the center high-mount stop lamp and disconnect the wire connector.
4. Lower the rear half of the headliner. Use lightweight wood or foam blocks to hold the headliner down.
5. Remove the electrical connectors from the bus bars, rear window defogger. Locate the electrical connectors so as not to damage the wiring/connectors when using the urethane power removal tool.
6. Remove the roof side outer rear panel. Refer to Roof Side Outer Rear Panel Replacement in Roof.
7. Remove the quarter panel fasteners at the lock pillar and the upper gutter area. Use lightweight wood or foam blocks to hold the quarter panel out.

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.

Notice: Care must be taken not to damage the roof when using power glass removal tool.

8. With the power glass removal tool, cut the urethane seal along the roof, down the sides and along the rear window lower panel between the rear compartment lid hinges from inside of the vehicle.
9. Use piano wire to cut the urethane at the lower corners. Feed the wire under the glass at the C-pillar through the inside and back out at the rear window lower panel, then around the outside of bead. Use a sawing motion to cut the urethane.
10. With the aid of a helper, remove the window assembly.
11. 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 the window assembly, if being reused.

### Installation Procedure

Notice: Loose material and/or a rough surface on remaining urethane may cause sealing problems during installation.

Important: The glass anti-slide clips will be damaged in the removal process. Make certain the anti-slide clips are replaced with new service parts. Do not slide the adjuster upward until the window assembly is installed.

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

Important: If applied molding becomes loose from the edge of the glass, clear and black prime the affected area. Allow to air dry. Apply a thin bead of urethane and install the molding.

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.

2. Preparation for window installation:

• | If the existing rear window assembly will be used:

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

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

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

• | If a new rear window assembly will be used:

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

- | Wipe the area dry with a clean lint-free cloth.

3. Tape the rear compartment lid in a half open position to provide clearance for installing the glass.
4. Prime the window opening area.

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

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

| Important: Use the line along the top of the rear window assembly below the rear window assembly 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 the primer to dry 5 minutes before applying the urethane.

5. Apply a smooth and 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 Dimension

• | Minimum Width: Dimension (B) 10 mm (0.39 in).

• | Minimum Height: Dimension (C) 14 mm (0.55 in).

6. With the aid of a helper, lift the glass into the window opening. Use the notches in the roof panel to center the glass to the vehicle. Make certain the lip of the applied molding laps over the roof feature line.

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.

7. Slide the adjuster on the anti-slide clips upward to position the glass up/down.

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.

8. Press the 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 the roof.
9. Watertest the vehicle at once using a soft spray. Use warm or hot water if available. Do not direct a hard stream of water on fresh adhesive material. Water applied on top of urethane adhesive, either during watertest or part of a separate operation, will speed up the cure of urethane.

Notice: Refer to Fastener Notice in the Preface section.

10. Inspect for leaks from inside the vehicle. Paddle in extra adhesive at leak points using a tongue depressor or similar flat flexible tool.
11. Install the quarter panel fasteners.

Tighten
Tighten the fasteners to 9 N·m (80 lb in).

12. Install the roof side outer rear panel. Refer to Roof Side Outer Rear Panel Replacement in Roof.
13. Connect the electrical connectors to bus bar.
14. Install the headliner.
15. Install the center high-mount stop lamp.
16. Install the center high-mount stop lamp cover.
17. Install the rear window trim finish panel. Refer to Upper Rear Trim Finish Panel Replacement in Interior Trim.

## Rear 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.

Important: Both body lock pillar upper moldings must be removed.

1. Remove the rear window trim finish panel. Refer to Upper Rear Trim Finish Panel Replacement in Interior Trim.
2. Remove the center high-mount stop lamp cover.
3. Remove the fasteners from the center high-mount stop lamp and disconnect the wire connector.
4. Lower the rear half of the headliner. Use lightweight wood or foam blocks to hold the headliner down.
5. Remove the electrical connectors from the bus bars.
6. Remove the rear compartment lid weatherstrip at the rear window lower panel.
7. Remove the roof front drip molding. Refer to Roof Front Drip Molding Replacement - Left Side and Roof Front Drip Molding Replacement - Right Side in Roof.
8. Remove the tail lamps and disconnect the wire connectors.
9. Remove the quarter panel fasteners at the lock pillar, tail lamp opening, and the upper gutter area. Use lightweight wood or foam blocks to hold the quarter panel out.
10. If the backglass is to be reused, protect the lower molding by folding it over on itself and securing it with masking tape.
11. If re-using the backglass, apply two 152 mm (6 in) pieces of duct tape to the top and bottom of the glass to prevent it from falling out when the urethane adhesive is 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.

Notice: Care must be taken not to damage the roof when using power glass removal tool.

Notice: Using thick tape, tape quarter glass encapsulation to protect from damage.

12. Using a power glass removal tool, cut the urethane seal along the roof from inside, and the urethane seal along the sides and bottom, from outside of the vehicle.
13. Using piano wire, cut the urethane seal along the bottom corners and side of the windshield in areas as shown in the illustration.

Important: Rear compartment lid must be in the full open position.

14. With the aid of a helper, remove the window assembly.

### 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. 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.

Tape the rear compartment lid in a half open position to provide clearance for installing the glass.

Important: The glass anti-slide clips will be damaged in the removal process. Make certain the anti-slide clips are replaced with new service parts. Do not slide the adjuster upward until the window assembly is installed.

2. Clean the entire window opening 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.

3. Preparation for window installation:

• | If the existing rear window assembly will be used:

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

- | 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 rear window assembly or the urethane.

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

• | If a new rear window assembly will be used:

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

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

4. Prime the window opening area.

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

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

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

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

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

5. Apply a smooth and 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 Dimension

• | Minimum Width: Dimension (B) 13 mm (0.51 in).

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

6. With the aid of a helper, lift the glass into the window opening. Use the notches in the roof panel to center the glass to the vehicle. Make certain the lip of the applied molding laps over the roof feature line.
7. Slide the adjuster on the anti-slide clips upward to position the glass up/down.

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.

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 equivalent, tape glass up to the roof.
9. Watertest the vehicle at once using a soft spray. Use warm or hot water if available. Do not direct a hard stream of water at fresh adhesive material. Water applied on top of the urethane adhesive, during 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 leak points using a tongue depressor or similar flat flexible tool.
11. Install the rear compartment lid weatherstrip.
12. Remove the blocks that hold the quarter panels outboard and install the fasteners.
13. Install the tail lamps.
14. Install the roof front drip molding. Refer to Roof Front Drip Molding Replacement - Left Side and Roof Front Drip Molding Replacement - Right Side in Roof.
15. Remove the blocks used to hold headliner down.
16. Connect the electrical connectors to the bus bars.
17. Install the center high-mount stop lamp.
18. Install the center high-mount stop lamp cover.
19. Install the rear window trim finish panel. Refer to Upper Rear Trim Finish Panel Replacement in Interior Trim.