COMPARTMENT LIFT WINDOW METAL PANEL REMOVAL AND ADJUSTMENT

CAUTION:

WHEN WORKING WITH GLASS ASSEMBLIES, THE USE OF PERSONAL PROTECTION ITEMS, SUCH AS, WORK GLOVES AND EYE PROTECTION SHOULD BE WORN TO REDUCE THE CHANCE OF PERSONAL INJURY SHOULD THE GLASS BREAK. 1.PLACE PROTECTIVE COVERINGS AROUND THE BODY OPENING. 2.PLACE TWO (2) JACKSTANDS IN THE BODY TO SUPPORT THE GLASS, PLACE PROTECTIVE COVERING OVER THE JACKSTANDS. 3.DISCONNECT THE ELECTRICAL CONNECTORS FROM THE REAR END OF THE GAS SUPPORT (IF PRESENT) AND REMOVE THE BOLTS RETAINING THE GAS SUPPORT TO THE LOWER REINFORCEMENT. 4.LOWER THE GLASS. 5.REMOVE: A.WIPER MOTOR AND BLADE ASSEMBLY (IF PRESENT). B.GAS SUPPORTS C.LOCK STRIKER D.NUTS HOLDING THE LOWER REINFORCEMENT TO THE PANEL STARTING THE WITH OUTBOARD NUTS. E.SCREWS RETAINING THE LIFT WINDOW MOULDING TO THE PANEL. 6.REMOVE THE PANEL FROM THE GLASS. A.MASK OFF THE TOP FORWARD EDGE OF THE PANEL NEXT TO THE GLASS. B.USING A FLAT-BLADED SHARP TOOL CUT OUT THE FOAM AND BUTYL SEALING STRIPS BETWEEN THE PANEL AND THE GLASS. CLEAN THE TOOL FREQUENTLY TO EASE THE CUTTING OPERATION. C.USING A SHARP-BLADED UTILITY KNIFE, CUT THE URETHANE BETWEEN THE NYLON PATCHES AND THE GLASS. NEW PATCHES WILL BE REQUIRED WHEN INSTALLING THE PANEL TO THE GLASS. D.LIFT UPWARD ON THE PANEL AND PULL IT FROM THE GLASS, BEING CAREFUL NOT TO DISTORT THE ENDS OF THE GLASS MOULDING. 7.CLEANING A.USING A RAZOR BLADE AND CLOTH DAMPENED WITH ALCOHOL, CLEAN ALL ADHESIVE FROM THE GLASS. B.CLEAN ALL ADHESIVE FROM THE PANEL AS A BENCH OPERATION. C.PLACE A SMALL PIECE OF BUTLY ON THE BUSHING SIDE OF ALL BLACK SPACERS WITH INTEGRAL BUSHINGS. 8.INSTALL A.FOAM SEALING STROP (PART NUMBER 20328200) TO THE FORWARD EDGE OF THE PANEL (FIGURE 1, ITEM #1). B.BUTYL ADHESIVE STRIP (5/15 SQUARE) (3M, PART NUMBER 08631), NEXT TO THE SEALING STRIP (FIGURE 1, ITEM #2). 9.SEAL THE ORIGINAL HOLES IN THE PANEL, WHERE THE GLASS MOULDING RETAINING SCREWS WERE INSTALLED WITH BUTYL. 10.PRIME THE AREA SHOWN IN DIGURE 2 WITH BLACK PRIMER FROM THE URETHANE KIT.* ALLOW IT TO AIR DRY FOR FIVE MINUTES. 11.INSTALL URETHANE (PART NUMBER 9636067 OR EQUIVALENT)* TO THE AREA PRIMED IN THE ABOVE STEP AND SMOOTH THE MATERIAL USING A FLAT-BLADED TOOL OR TONGUE DEPRESSOR. 12.WITH THE AID OF A HELPER LOCATE THE PANEL TO THE GLASS IN THE REAR MOST POSITION. 13.ASSEMBLE PANEL TO GLASS. A.PLACE BLACK SPACERS WITH BUSHING OVER THE STUDS WITH THE BUSHING END OF THE SPACER GOING THROUGH THE GLASS. B.LOCATE THE LOWER REINFORCEMENT OVER THE STUDS (FIGURE 3, ITEM #1). C.HAND TIGHTEN ALL NUTS RETAINING THE PANEL TO THE GLASS. D.LOCATE THE NYLON PATCHES TO THE GLASS BEING SURE OF RIGHT AND LEFT HAND INSTALLATION. 14.LOWER THE LIFT WINDOW AND ALIGN THE PANEL TO THE GLASS TO THE BODY. 15.FROM INSIDE OF THE CAR, HAND TIGHTEN THE NUTS. 16.RAISE THE LIFT WINDOW AND PLACE JACKSTANDS IN LOCATION TO SUPPORT THE LID. CAUTION: WHEN PERFORMING THE NEXT OPERATIONS, DO NOT TIGHTEN BEYOND THE SPECIFIED TORQUE OR GLASS BREAKAGE AND PERSONAL INJURY COULD RESULT. 17.USING A TORQUE WRENCH, TIGHTEN THE RETAINING NUTS TO 16 N.M (11 FT. LBS.) IN THE FOLLOWING ORDER: A.FORWARD CENTER B.REARWARD CENTER C.ALL REMAINING 18.INSTALL THE MOULDING TO THE PANEL. IT MAY BE NECESSARY TO DRILL NEW HOLES FOR THE RETAINING SCREW. 19.INSTALLING GAS SUPPORTS. A.INSTALL BOLTS - GAS SUPPORT TO BODY AT THE RIGHT AND LEFT HAND GAS SUPPORTS. MAKE SURE THE ELECTRICAL CONNECTOR IS FACING INBOARD. TORQUE BOLTS TO 20-28 N.M (15-20 FT. LBS.), FIGURE 4, VIEW B. B.CONNECT THE ELECTRICAL CONNECTOR TO THE GAS SUPPORT (IF PRESENT). C.INSTALL THE BOLTS AT THE REAR OF THE GAS SUPPORTS TO THE LOWER REINFORCEMENT. TORQUE BOLTS TO 5-7 N.M (40-60 INCH LBS.) AND CONNECT THE ELECTRICAL CONNECTOR (IF PRESENT), FIGURE 4, VIEW A. 20.LIFT THE LID AND REMOVE THE JACKSTANDS FROM THE BODY. 21.INSTALL: A.STRIKER TO PANEL B.WIPER MOTOR AND BLADE ASSEMBLY. TORQUE THE NUT RETAINING THE WIPER MOTOR TO THE GLASS TO 5-7 N.M (40-60 INCH LBS.). 22.ALIGN THE LOCK A.CAREFULLY CLOSE THE LID AND CHECK THE STRIKER TO LOCK ENGAGEMENT. B.IF THE STRIKER DOES NOT ENGAGE THE LOCK CORRECTLY, LOOSEN THE REAR END TRIM PANEL AND LOOSEN THE BOLTS HOLDING THE LOCK ASSEMBLY TO THE REAR END PANEL, IF EQUIPPED WITH ELECTRICAL LOCK RELEASE SOLENOID, LOOSEN THE BOLT HOLDING THE SOLENOID TO THE REAR END PANEL. C.ADJUST THE LOCK FOR PROPER ENGAGEMENT TO THE STRIKER. D.TIGHTEN THE LOCK AND SOLENOID RETAINING BOLTS TO 9-12 N.M (7-9 FT. LBS.). E.REPLACE THE REAR END TRIM PANEL. 23.REPLACE THE LIFT WINDOW TRIM PANEL. DOMINION SURE SEAL EQUIVALENT URETHANE PT. # CUS - BLACK PRIMER PT. # CUSP1 - CLEAR PRIMER PT. #CUSP2 - BLACK

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