Rear Window Replacement
REMOVAL PROCEDURERear Window Replacement: Removal Procedure:
Tools Required
^ J 39040 Quarter Glass Remover
^ J 41993 Windshield Blade
^ Solvent for cleaning the edge of the window use GM Glass Cleaner PIN 1050427 or Isopropyl
^ Cartridge-type caulking gun
^ Commercial type razor knife for cutting around the edges of the windows.
^ Rubber suction cups.
CAUTION
^ When replacing stationary windows, Urethane Adhesive Kit GM PIN 12346284, or a urethane adhesive system meeting GM Specification GM3651M, must be used 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.
^ When working with any type of glass, use approved safety glasses and gloves to reduce the chance of personal injury.
1. Mask off the area around the rear window to protect the paint.
2. Open the rear compartment lid.
3. Remove the rear window reveal moldings from the reveal molding retainers.
4. Remove rear quarter trim finish panel.
5. Remove rear window defogger electrical connectors from right and left side of rear window.
6. Remove the rear window garnish molding.
7. Check the clearance of the headliner to the window.
8. Protect the headliner as necessary. Ensure the corners are protected.
9. Mask the area around the rear window to protect the painted surfaces and mask the area around the rear window to aid in the clean up after the windshield is installed.
10. Perform the following steps to cut out the rear window:
10.1. Use the J 39040 with the J 41993.
10.2. Keep the J 41993 as close to the rear window as possible to prevent damage to the following components:
^ To prevent damage to the headliner.
^ To prevent damage to the painted surfaces.
11. Using suction cups and with the aid of a helper remove the rear window from the opening.
INSTALLATION PROCEDURE
Rear Window Replacement: Installation Procedure:
1. Install rear window with the aid of a helper, dry fit the window in the opening to determine the correct position of the windshield by:
^ Position windshield in the opening.
^ Using masking tape, mark the location of the window in the opening.
^ Slit the masking tape at the window edge.
^ Remove window from the opening an place it inside up on a clean protected surface.
2. Clean the surface of the window to which urethane adhesive will contact (around edge of inside surface) with a clean isopropyl dampened cloth, or with GM Window Cleaner P/N 1050427 or equivalent.
3. Repair the opening as indicated:
^ If the extended method is being used, shake pinchweld primer # 3 (black) well, and apply to any exposed painted surfaces (or scratches to bare metal) on the pinchweld flange. Allow to dry for 10 minutes.
^ If short method is being used, DO NOT prime the existing bead of urethane on the body.
IMPORTANT: If corrosion of the pinchweld flange is present, or if sheet metal repairs or replacements are required, the pinchweld flange must be refinished to present a clean Primer Only surface.
If paint repairs are required, mask the flange bonding area (prior to applying the colour coat) to provide a clean Primer Only surface.
4. After repairing the opening as indicated, Shake the pinchweld primer # 3 (black) well, and using a new dauber, apply to the primed surface of the flange in the bonding area. Allow to dry for 10 minutes.
5. If the original window is being reused, remove any existing urethane adhesive from the window edge and surface using a razor knife or equivalent.
6. If original reveal molding or new production type reveal molding is being used, install molding to window.
7. Install new acoustic strip on windshield, if necessary.
8. If extended method is being used, apply a dam material, such as Norton Windshield Dam Replacement or equivalent, approximately 12 mm to 18 mm (1/2 inch to 5/8 inch) (depending on the width of the pinch weld) from the outer edge of the window, around the perimeter of the window to control urethane squeeze out.
IMPORTANT: Care should be taken to prevent clear primer from running into the vision area of the window. This primer dries almost instantly, but may stain the viewing area of the window if not applied evenly.
Rear Window Replacement: Installation Procedure:
9. Using a new dauber, apply glass prep # 1 (clear) for approximately 10 mm to 16 mm (3/8 to 5/8 inch) around the entire perimeter of the inner surface and any exposed edges of the window. Wipe dry with a clean cloth.
10. Shake window primer # 2 (black) well, and using a new dauber, apply primer to the same areas that window prep # 1 (clear) were applied to. Allow to dry for approximately 6 to 10 minutes.
Rear Window Replacement: Installation Procedure:
11. Cut the tip of the application nozzle:
^ If short method is being used, cut the tip of the application nozzle to provide a bead of approximately 4.5 mm (1/8 inch) to 3/16 diameter.
^ If extended method is being used, cut the tip of the application nozzle at a 45°angle with a 13 mm (1/2 in) groove to provide a bead of approximately 8 mm (5/16 in) wide x 13 mm high (5/16 in x 1/2 in).
Rear Window Replacement: Installation Procedure:
12. Using a cartridge type caulking gun, apply a smooth continuous bead of urethane adhesive;
12.1. Apply urethane adhesive to the existing bead of urethane adhesive on the body when using the short method.
12.2. Apply urethane adhesive to the edge of the window (or inside edge of the revealing molding in certain cases) as a guide for the nozzle, apply urethane to the inner surface of the window, when using the extended method.
Rear Window Replacement: Installation Procedure:
13. Install the rear window reveal molding (1) into the reveal molding retainers (2).
Rear Window Replacement: Installation Procedure:
14. Using suction cups, and with the aid of a helper, position the rear window in the opening and align to the previously installed masking tape.
15. Press the window firmly into place until the reveal molding is flush with the surrounding sheet metal.
16. Tape the window to the body to minimize movement and clean up any urethane squeeze out from body.
17. Watertest the window immediately using a soft spray. Warm or hot water is preferred to accelerate the cure of the adhesive. DO NOT direct a hard stream of high pressure water at fresh urethane adhesive.
17.1. Refer to Water Hose Test in Waterleaks.
17.2. If leaks are found, apply extra urethane adhesive at leak point using a plastic paddle.
18. Install the remaining revealing moldings if necessary and remove protective tape and coverings.
IMPORTANT: Allow the vehicle to remain at room temperature (22 degrees Celsius/72 degrees Fahrenheit at 30% relative humidity) for a minimum of six hours.
Partially lower a door window to prevent pressure build ups when closing doors prior to urethane adhesive cure.
DO NOT DRIVE VEHICLE until urethane adhesive is cured (minimum of 6 hours at room temperature).
DO NOT USE COMPRESSED AIR to dry urethane adhesive.
19. Install the rear window garnish molding.
20. Install rear window defogger electrical connectors from right and left side of rear window.
21. Install rear quarter trim finish panel.
22. Remove masking tape from around the rear window.