COMPARTMENT LIFT WINDOW GLASS REPLACEMENT AND ADJUSTMENT

REMOVAL PROCEDURE 1.PLACE PROTECTIVE COVERING ALONG THE EDGES OF THE REAR COMPARTMENT TO PREVENT DAMAGE TO PAINTED SURFACES. 2.IF THE GLASS IS BROKEN, CLEAN ALL BROKEN GLASS FROM THE INTERIOR OF THE VEHICLE. 3.FROM INSIDE OF THE CAR, REMOVE THE PLASTIC COVERS FROM BOLTS FOR GAS SUPPORTS TO BODY. 4.IF EQUIPPED WITH HEATED BACK GLASS, REMOVE THE WIRE CONNECTORS FROM THE GAS SUPPORTS. A.UNLOCK THE REAR COMPARTMENT LIFT WINDOW. B.HAVE A HELPER SUPPORT THE LID IN A PARTIALLY OPEN POSITION. 5.REMOVE A.BOLTS HOLDING THE GAS SUPPORTS TO THE BODY. B.BACK BODY OPENING UPPER GARNISH MOULDING. C.NUTS RETAINING THE LIFT WINDOW HINGE TO THE BODY. 6.WITH THE AID OF A HELPER REMOVE THE LIFT WINDOW FROM THE CAR AND PLACE IT UPSIDE DOWN ON A PROTECTED SURFACE. NOTE THE POSITION OF ANY HINGE SHIMS (IF PRESENT). 7.REMOVE: A.GAS SUPPORTS FROM THE LOWER REINFORCEMENT. B.HINGE ASSEMBLIES FROM THE GLASS. C.TRIM PANEL. D.WIPER AND BLADE ASSEMBLY (IF PRESENT). E.LOCK STRIKER. F.ELECTRICAL CONTACT AND WIRING HARNESS (IF PRESENT). G.LOWER REINFORCEMENT (FIGURE 1, ITEM #1). H.SCREWS HOLDING THE GLASS FINISHING MOULDING TO THE PANEL. I.NYLON PATCHES AT THE RADIUS JOINT OF THE PANEL BY CUTTING THROUGH THE ADHESIVE USING A CURVED BLADE UTILITY KNIFE. 8.WITH THE AID OF A HELPER, TURN THE LIFT WINDOW OVER AND PLACE MASKING TAPE ALONG THE TOP EDGE OF THE PANEL. A.IF GLASS IS BEING REPLACED FOR ANY REASON OTHER THAN BREAKAGE, USE A FLAT-BLADED SHARP TOOL TO CUT OUT THE FOAM AND BUTYL SEALING STRIPS BETWEEN THE PANEL AND GLASS. CLEAN THE TOOL FREQUENTLY TO EASE CUTTING OPERATION. B.LIFT UPWARD ON THE PANEL AND PULL IT FROM THE GLASS BEING CAREFUL NOT TO DISTORT THE ENDS OF THE GLASS MOULDING. 9.CLEAN THE PANEL OF FOAM SEALING STRIP AND ALL ADHESIVES. THIS CAN BE DONE BY USING A CLOTH DAMPENED IN ALCOHOL. 10.REMOVE THE LOWER GLASS SEALING STRIPS (FIGURE 2, ITEM #5). 11.REMOVE AND DISCARD THE PLASTIC SPACERS. INSTALLATION 1.IF A NEW GLASS IS TO BE INSTALLED, NEW GLASS FINISHING MOULDINGS WILL BE REQUIRED. TO INSTALL MOULDING TO GLASS: A.USE CLEAR PRIMER IN URETHANE KIT 9636067.* APPLY THE PRIMER TO THE GLASS AS SHOWN IN FIGURE 3. B.INSTALL THE RIGHT AND LEFT HAND GASKETS TO THE TABS ON GLASS MOULDING AS SHOWN IN FIGURE 4, ALIGN THE HOLES IN THE GASKETS TO THE HOLES IN THE MOULDING TABS. C.APPLY A 4.5 MM OR 3/16 INCH BEAD OF URETHANE FROM THE KIT INTO THE MOULDING CHANNEL AS SHOWN IN FIGURE 5. DO NOT APPLY URETHANE FOR A DISTANCE OF 25 MM OR 1 INCH FROM THE CENTRE END OF EACH MOULDING.* D.PLACE THE MOULDING ESCUTCHEON INSIDE THE RIGHT AND LEFT HAND MOULDINGS (FIGURE 2, ITEM #7). E.USING A RUBBER MALLET, INSTALL THE MOULDINGS ONTO GLASS MAKING SURE TO ALIGN THE HOLES IN THE TABS OF THE MOULDING WITH HOLES IN THE GLASS. BE SURE THE CORNER AREA IS FULLY SEATED. CAUTION: WHEN PERFORMING THE NEXT OPERATION, DO NOT TIGHTEN BEYOND THE SPECIFIED TORQUE OR GLASS BREAKAGE AND PERSONAL INJURY COULD RESULT. 2.INSTALL THE HINGE TO THE GLASS TORQUE BOLTS 16 N.M (11 FT. LBS.). 3.INSTALL THE FOLLOWING ITEMS: A.GLASS TO REINFORCEMENT SEALS TO REAR EDGE OF GLASS (FIGURE 1, ITEM #4). B.FRONT SEALING STRIP (PART NUMBER 20328200), FIGURE 6, ITEM #1. C.BUTYL ADHESIVE STRIP (5/16 SQUARE), 3M - PART NUMBER 08631, NEXT TO THE SEALING STRIP, FIGURE 6, ITEM #2. SEAL THE HOLES IN THE PANEL WHERE THE GLASS MOULDING SCREWS WERE INSTALLED USING ABOVE BUTYL. D.APPLY BLACK PRIMER (FROM KIT) TO THE PANEL, FIGURE 7. ALLOW TO AIR DRY FOR 5 MINUTES.* E.APPLY URETHANE (PART NUMBER 9636067) TO THE AREA OF THE PANEL PRIMED IN THE ABOVE STEP.* SMOOTH THE URETHANE WITH A FLAT-BLADED TOOL. IF A NEW PANEL IS TO BE INSTALLED, ALSO APPLY IT TO THE FORWARD OUTER DRAIN HOLES (FIGURE 7, VIEW A). 4.INSTALL PANEL TO GLASS. A.PLACE NEW GLASS SPACERS OVER THE FORWARD STUDS ON THE PANEL (IF ORIGINAL GLASS WAS BROKEN), FIGURE 6, ITEM #3). B.PLACE THE GLASS ON THE PANEL BY PLACING THE HOLES IN THE GLASS OVER THE STUDS ON THE PANEL. ALIGN THE PANEL TO THE GLASS IN THE REAR MOST POSITION. C.PLACE SPACERS BETWEEN THE GLASS AND THE LOWER REINFORCEMENT. D.PLACE THE LOWER REINFORCEMENT OVER THE STUDS ON THE PANEL (FIGURE 1, ITEM #1). E.APPLY NYLON PATCHES TO THE GLASS (BEING SURE OF RIGHT AND LEFT HAND PART INSTALLATION. F.HAND TIGHTEN ALL NUTS RETAINING THE REINFORCEMENT TO THE PANEL. G.WITH THE AID OF A HELPER, INSTALL THE REAR COMPARTMENT LIFT WINDOW ASSEMBLY TO THE BODY. IF THE GLASS NEEDS ADJUSTMENT TO THE BODY, THE HOLES FOR THE HINGE BODY BOLTS ARE OVERSIZED WHICH ALLOWS FOR SOME ADJUSTMENT. INSTALL ORIGINAL HINGE SHIMS TO THE BODY. ONCE THE GLASS IS PROPERLY ALIGNED, TORQUE THE HINGE TO BODY BOLTS TO 20-28 N.M OR 15-20 FT.-LBS. (FIGURE 8). H.FROM INSIDE THE CAR, LOOSEN THE LOWER REINFORCEMENT TO PANEL NUTS. I.FROM OUTSIDE THE CAR, POSITION THE REAR PANEL CENTRED AND FORWARD 3 MM OR 1/8 INCH OF THE FINAL DESIRED POSITION. J.FROM INSIDE THE CAR, HAND TIGHTEN THE LOWER REINFORCEMENT TO PANEL NUTS. K.RAISE AND PROP OPEN THE REAR COMPARTMENT LIFT WINDOW. CAUTION: WHEN PERFORMING THE NEXT OPERATIONS, DO NOT TIGHTEN BEYOND THE SPECIFIED TORQUE OR GLASS BREAKAGE AND PERSONAL INJURY COULD RESULT. 1.TIGHTEN THE RETAINING NUTS TO 16 N.M OR (11 FT.-LBS.) IN THE FOLLOWING ORDER: - FORWARD CENTRE - REAR CENTRE - ALL REMAINING NUTS M.INSTALL THE SCREWS SECURING THE GLASS FINISHING MOULDING TO THE PANEL. IT MAY BE NECESSARY TO DRILL TWO (2) SMALL HOLES IN THE PANEL FOR THE MOULDING RETAINING SCREWS. 5.WHILE A HELPER SUPPORTS THE LIFT WINDOW, INSTALL THE GAS SUPPORTS TO THE BODY. BE SURE THAT THE ELECTRICAL CONTACT AT THE FORWARD EDGE OF THE GAS SUPPORT (IF PRESENT) IS INBOARD, THEN: A.TORQUE THE GAS SUPPORT TO BODY BOLTS TO 20-28 N.M OR 15-20 FT.-LBS. B.TORQUE THE GAS SUPPORT TO LIFT WINDOW BOLTS 5-7 N.M (40-60 INCHES). C.REINSTALL THE WIRING HARNESS AND THE UPPER ELECTRICAL CONTACT TO THE LIFT WINDOW PANEL (IF PRESENT). D.INSTALL THE WIPER MOTOR TO THE LIFT WINDOW (IF PRESENT) TORQUE ALL BOLTS 5-7 N.M (3.5 TO 5 FT.-LBS.). E.INSTALL THE LOCK STRIKER TO THE LIFT WINDOW PANEL AND CAREFULLY CHECK THE LOCK STRIKER TO LOCK ENGAGEMENT. F.IF IT IS NECESSARY TO ADJUST THE LOCK FOR PROPER ENGAGEMENT OF THE STRIKER, REMOVE THE REAR END TRIM PANEL. G.LOOSEN THE BOLTS HOLDING THE LOCK TO THE REAR END PANEL (AND SOLENOID IF PRESENT). H.ADJUST THE LOCK FOR PROPER ENGAGEMENT OF THE STRIKER. I.TIGHTEN ALL BOLTS TO A TORQUE OF 9-12 N.M (7-9 FT.-LBS.). J.INSTALL THE TRIM PREVIOUSLY REMOVED. DOMINION SURE SEAL EQUIVALENT URETHANE PT. #CUS - BLACK PRIMER PT. #CUSP1 - CLEAR PRIMER PT. #CUSP2 - BLACK

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