COMPARTMENT LIFT WINDOW MOLD REMOVAL AND INSTALLATION. Pontiac J2000 1982

For 1990-2009 cars

# COMPARTMENT LIFT WINDOW MOLD REMOVAL AND INSTALLATION

#### CAUTION:

WHEN WORKING WITH GLASS ASSEMBLIES, THE USE OF PERSONAL PROTECTION ITEMS, SUCH AS, WORK GLOVES AND EYE PROTECTION IS RECOMMENDED TO REDUCE THE CHANCE OF PERSONAL INJURY SHOULD THE GLASS BREAK. REMOVAL 1.REMOVE THE COMPARTMENT LIFT WINDOW FROM THE BODY AS OUTLINED IN THE BODY PORTION OF THE CAR DIVISION SERVICE MANUAL AND PLACE IT UPSIDE DOWN ON A PROTECTED SURFACE. 2.REMOVE THE BOLTS HOLDING THE UPPER HINGE REINFORCEMENT TO THE GLASS (FIGURE 1). 3.USE PIANO WIRE TO CUT THE ADHESIVE BETWEEN THE REINFORCEMENT AND THE GLASS AND REMOVE THE REINFORCEMENT. 4.REMOVE THE RUBBER BUMPERS AND THE STUDS HOLDING THE FINISHING MOULDING TO THE PANEL (FIGURE 3). 5.REMOVE THE PLASTIC FILLER (IF PRESENT) (FIGURE 3). 6.REMOVE THE SPACERS UNDER THE TAB OF MOULDING (FIGURE 2). CAUTION: TO REDUCE THE CHANCE OF PERSONAL INJURY, PERFORM THE URETHANE BURN-OUT OPERATION IN A WELL VENTILATED AREA AND AVOID INHALING THE FUMES BEING EMITTED AS THESE FUMES MAY BE HAZARDOUS. 7.USING AN ACETYLENE TORCH, WITH A NUMBER 2 TIP, START AT THE TOP OF EITHER THE RIGHT OR LEFT SIDE MOULDING AND APPLY HEAT FROM A DISTANCE OF 200 MM (8 INCH) TO THE OUTBOARD EDGE OF THE MOULDING FOR 30 TO 60 SECONDS USING A BACK AND FORTH MOTION. 8.IMMEDIATELY GRASP THE HEATED SECTION OF THE MOULDING WITH PLIERS AND PULL THE MOULDING AWAY FROM THE GLASS. 9.REPEAT STEPS 7 AND 8 FOR THE ENTIRE LENGTH OF THE MOULDING. 10.DO THE SAME PROCEDURE OUTLINED IN STEPS 7 THROUGH 9 FOR THE OPPOSITE SIDE MOULDING. INSTALLATION 1.CLEAN ALL THE ADHESIVE FROM THE GLASS AND THE UPPER HINGE REINFORCEMENT USING A RAZOR BLADE AND A CLOTH DAMPENED WITH ALCOHOL OR OIL-FREE NAPHTHA. 2.APPLY THE BLACK PRIMER FROM THE URETHANE KIT, PART NUMBER 9636067 OR EQUIVALENT, DOMINION SURE SEAL URETHANE PT #CUS CLEAR PRIMER PT #CUSP1 BLACK PRIMER PT #CUSP2 OR COMPLETE URETHANE KIT PT# CUSE (GOOD FOR ONE VEHICLE ONLY) TO THE INSIDE CHANNEL OF THE MOULDING SECTIONS. ALLOW TO AIR DRY FOR 5 MINUTES (FIGURE 5). A.APPLY THE CLEAR PRIMER TO THE EDGE OF THE GLASS ON ALL THREE SIDES; THEN APPLY THE BLACK PRIMER TO THE SAME AREAS. ALLOW TO AIR DRY FOR 5 MINUTES (FIGURE 6). B.INSERT THE ESCUTCHEON INTO THE MOULDING ENDS (FIGURE 5). C.APPLY A 3 MM (1/8 INCH) BEAD OF URETHANE ADHESIVE INTO THE MOULDING CHANNEL (FIGURE 4, VIEW B). D.APPLY A SECOND 3 MM (1/8 INCH) BEAD OF URETHANE FOR A DISTANCE OF 125 MM (5 INCH) AT THE LOWER ENDS OF THE MOULDING (FIGURE 4, VIEW C). E.PLACE THE NEW MOULDING ASSEMBLY ON THE GLASS. ALIGN THE HOLES IN THE TAB OF THE MOULDING TO THE HOLES AT THE TOP OF THE GLASS. F.PLACE SPACER BETWEEN THE GLASS AND THE TABS OF THE MOULDING (FIGURE 2). G.USING A CLEAN RUBBER MALLET, DRIVE THE MOULDINGS ONTO THE GLASS STARTING AT THE UPPER CORNERS. H.APPLY CLOTH TAPE EVERY 200 MM (3 INCH) OVER THE MOULDINGS AND THE GLASS SIDES TO KEEP THE MOULDING IN PLACE WHILE THE URETHANE CURES. 3.INSTALL THE STUDS THROUGH THE PLASTIC FILLER SUPPORT (IF REMOVED) AND INTO THE PANEL AND TIGHTEN 8 TO 10 N.M (6 TO 7 FT-LB) (FIGURE 3). 4.INSTALL THE BUMPERS ONTO THE STUDS (FIGURE 3). 5.USING THE BLACK PRIMER, PRIME THE GLASS SIDE OF THE UPPER REINFORCEMENT. ALLOW IT TO AIR DRY FOR 5 MINUTES. A.PRIME THE GLASS WITH CLEAR AND THEN BLACK PRIMER WHERE THE REINFORCEMENT WILL BE BONDED TO THE GLASS. ALLOW IT TO AIR DRY FOR 5 MINUTES (FIGURE 6, VIEW A). B.APPLY A 3 MM (1/8 INCH) ROUND BUTYL STRIP AROUND THE PERIMETER OF THE REINFORCEMENT (FIGURE 1, SECTION A-A) C.APPLY A 5 MM (1/4 INCH) BEAD OF URETHANE ADHESIVE ON THE REINFORCEMENT NEXT TO THE BUTYL DAM. USE CARE NOT TO APPLY URETHANE NEAR THE BOLT HOLES (FIGURE 1, SECTION A-A). 6.LOCATE THE REINFORCEMENT ON THE GLASS. CAUTION: WHEN PERFORMING THE NEXT OPERATIONS, DO NOT TIGHTEN BEYOND THE SPECIFIED TORQUE OR GLASS BREAKAGE AND PERSONAL INJURY COULD RESULT. 7.FROM THE UNDERSIDE OF THE GLASS, INSERT BEAUTY BOLTS THROUGH THE HOLES IN THE GLASS AND THE HEX HOLES IN THE REINFORCEMENT (FIGURE 1, VIEW A). TIGHTEN THE NUTS TO 8 TO 10 N.M (6 TO 7 FT-LB). 8.INSTALL THE COMPARTMENT LIFT WINDOW TO THE BODY MAKING SURE OF PROPER ALIGNMENT. ALLOW THE URETHANE TO CURE FOR 6 HOURS.

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