Rear Window Replacement. Chevrolet PJJ 2001

For 1990-2009 cars

#### Tools Required

• | J 24402-A Glass Sealant (Cold Knife) Remover

• | J 39032 Stationary Glass Removal Tool

• | J 25070 Heat Gun

• | Urethane Adhesive Kit GM P/N 12346392 or Equivalent

• | Isopropyl Alcohol or Equivalent

• | Cartridge-type Caulking Gun

• | Commercial-type Utility Knife

• | Razor Blade Scraper

• | Suction Cups

• | Plastic Paddle

### Removal Procedure

Important: Before cutting out a stationary window, apply a double layer of masking tape around the perimeter of the painted surfaces and inner trim of the window.

1. Open the rear compartment lid in order to access the reveal molding (1).
2. Remove the rear window reveal molding (1). Refer to Rear Window Reveal Molding Replacement .
3. Remove the rear seat cushion. Refer to Rear Seat Cushion Replacement in Seats.
4. Remove the rear seat back. Refer to Rear Seat Back Replacement in Seats.
5. Remove the rear quarter trim panels. Refer to Rear Quarter Trim Panel Replacement in Interior Trim.
6. Disconnect the rear window electrical connectors.

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.

7. Use safety glasses and gloves.

Important: Keep the cutting edge of the tool against the window when removing. This will allow the urethane adhesive to be separated from the window and leave a base of urethane on the pinchweld flange. The only suitable lubrication is clear water.

8. Use the J 24402-A or J 39032 in order to cut the stationary window from the pinchweld flange. Do this from inside the vehicle in order to protect the outer paint surface.
9. With the aid of an assistant, use the suction cups in order to lift the rear window from the opening.

### Installation Procedure

1. Verify all primers and urethane adhesive are within expiration dates.

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.

2. Inspect the following components for the causes of a broken rear window:

• | The flange of the rear window opening

• | The rear window reveal molding

3. Inspect the following components in order to prevent possible future damage to the rear window:

• | A high weld

• | The flange of the rear window opening

• | Solder spots

• | Hardened spot weld sealer

• | Any obstruction or 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.

4. After repairing the opening as indicated, perform the following steps:
5. Inspect the condition of the stationary window opening and the urethane adhesive bead in order to determine which installation method you will use. Refer to Short Method Description or Extended Method Description for the guidelines.

5.1. | Remove no more of the window urethane adhesive than necessary in order to maintain the original shape. This will ensure the proper clearance between the window and the pinchweld flange of the opening.

5.2. | Clean around the inside edge of the inside surface of the window using GM Glass Cleaner P/N 1050427 or isopropyl alcohol.

6. After repairing the opening as indicated, shake the pinchweld primer (black #3) for at least one minute.

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.

7. Use a new dauber to apply the pinchweld primer( black #3) to the surface of the bonding area.
8. Allow the primer to dry for approximately 10 minutes. Ensure that all nicks and scratches are covered.
9. Install the new rear window reveal molding (1). Refer to Rear Window Reveal Molding Replacement .
10. Start from the center and hand press the rear window reveal molding (1) onto the rear window (2).
11. With the aid of an assistant, dry fit the stationary window in the opening in order to determine the correct way to position the stationary window in the opening.
12. Use masking tape in order to mark the location of the stationary window in the opening.
13. Slit the masking tape at the top edge of the stationary window.
14. With the aid of an assistant and the suction cups, remove the stationary window.
15. Place the rear stationary window on a clean, protected surface.
16. If the origianl rear window is being reused, remove all but approximately 2 mm (3/64 in) of the existing urethane adhesive from the rear window surface, using a utility knife or razor blade scraper.
17. Clean the inside surface of the stationary window to which urethane adhesive will be applied (around the edge of the inside surface) by wiping with a clean lint free cloth dampened with GM Glass Cleaner P/N 1050427 or equivalent.

Important: Do not remove all traces of the urethane adhesive, but all mounds or loose pieces should be removed.

18. If the extended method is being used remove all but approximately 2 mm (3/64 in) of the existing bead of adhesive from the pinchweld flange.
19. Shake the pinchweld primer (black #3) for at least one minute.

Important: Do not apply the (black #3 primer to the existing bead of the urethane adhesive. Apply only to nicks, scratches or the primed surfaces.

20. Use a new dauber to apply the primer to the surface of the pinchweld flange.
21. Allow the primer to dry for approximately 10 minutes.

Important: Use care when applying the stationary window prep (clear #1) in order to prevent the stationary window preparation from running into the vision area of the stationary window. This stationary window prep may stain the viewing area of the rear window if not applied evenly. This stationary window prep (clear #1) dries almost instantly.

22. If installing a new non encapsulated window:

22.1. | Use a new dauber, to apply the stationary window prep (clear #1) to an area approximately 10 to 16 mm (3/8 to 5/8 in) around the entire perimeter of the stationary glass inner surface (reference the illustration of the primer/bonding areas).

22.2. | Apply the stationary window prep (clear #1) to any exposed edges of the window.

22.3. | Wipe the primed area immediately with a lint-free cloth.

22.4. | Shake the glass primer (black #2) for at least one minute.

23. If installing a new encapsulated window:

23.1. | Use a new dauber, to apply the stationary window prep (clear #1) to an area approximately 10 to 16 mm (3/8 to 5/8 in) around the entire perimeter of the stationary glass inner surface (reference the illustration of the primer/bonding areas). The glass must be installed within 8 hours after applying the primer to the glass.

23.2. | The primed surface of the glass must be kept clean.

23.3. | Allow the glass primer to dry for approximately 10 minutes.

24. Shake the stationary window primer (black #2) for at least one minute.
25. Use a new dauber, in order to apply the stationary window primer (black #2) to the areas of the stationary window (1) to which prep (clear #1) was applied.
26. Allow the primer to dry for approximately 10 minutes.
27. If using the short method, cut the tip in order to provide an adhesive bead of approximately 6.0 mm (0.25 in).
28. If using the extended method, cut the tip in order to provide an adhesive bead of approximately 10.5 mm (0.14 in) wide and 10.5 mm (0.14 in) high.
29. Use a cartridge-type caulking gun, apply a smooth continuous bead of new urethane adhesive around the edge of the stationary window where the primer was applied.
30. When using the short method, apply the urethane adhesive to the existing bead of urethane adhesive on the body.
31. When using the extended method, use the edge of the stationary window or the inside edge of the reveal molding as a guide for the nozzle in order to apply the urethane adhesive (1) to the inner surface (2) of the stationary window (3).
32. With the aid of an assistant, use the suction cups in order to install the stationary window (1) into the opening.
33. Align the tape on the rear window and on the body.
34. Press the rear window firmly into place in order to wet-out and seat the urethane adhesive.
35. Tape the rear window in two places to the body in order to minimize movement until the urethane adhesive cures.
36. Clean any excess urethane adhesive from the body.

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

37. Use a soft spray of warm water in order to immediately water test the rear window.
38. Inspect the rear window for leaks.
39. If any leaks are found, use a plastic paddle in order to apply extra urethane at the leak point.
40. Retest the stationary window for leaks.

Caution: Insufficient curing of urethane adhesive may allow unrestrained occupants to be ejected from the vehicle resulting in personal injury.

• | For the moisture-curing type of urethane adhesive, allow a minimum of 6 hours at 21°C (70°F) or greater and with at least 30 percent relative humidity. Allow at least 24 hours for the complete curing of the urethane adhesive.

• | For the chemical-curing type of urethane adhesive, allow a minimum of 1 hour .

Do NOT physically disturb the repair area until after these minimum times have elapsed.
41. The following conditions must be maintained to properly cure the urethane:

41.1. | Partially lower a door window in order to prevent pressure buildups when closing doors before the urethane adhesive cures.

41.2. | Do not drive the vehicle until the urethane adhesive is cured. Refer to the above curing times.

41.3. | Do not use compressed air in order to dry the urethane adhesive.

42. Connect the rear window electrical connectors.
43. Install the rear quarter trim panels. Refer to Rear Quarter Trim Panel Replacement in Interior Trim.
44. Install the rear seat back. Refer to Rear Seat Back Replacement in Seats.
45. Install the rear seat cushion. Refer to Rear Seat Cushion Replacement in Seats.
46. Remove the protective coverings and tape from the vehicle and the headliner.
47. Close the rear compartment lid.