I see in a post that JeffryScott is insulating the roof of his 245. Lots of good tips there.
How do I do that with a 240 sedan?
I think I recall someone saying the rear windshield must be removed to get the liner out!
Would someone explain that process for me. The main thing is I don't want to break it. Certainly do not have a spare one of those hanging around.
Thanks.

I removed the rear glass in a similar process as Jessie mentions. It was a while ago but I think I used a wide flat head screw driver from the inside to lift up the lip of the rubber gasket in the lower corner and then threaded some mechanics wire through to the outside. The I think I used the flathead to fold the corner lip of the gasket into/on the mechanics wire while pulling up on the wire to expose the edge of the sheet metal edge. Then pushing the flathead between the sheet metal flange and the mechanics wire I was able to push the corner of the gasket lip to the other side of the sheet metal flange. Once that was set, it was just a matter of working the rubber lip slowly from the corner in each direction with the flathead screwdriver while also pushing on the corner of glass. Once you get so much of the rubber lip to the other side you can pull the glass from the outside and it just pops out.

Don't ask me how to put it back in though. As any manual would describe: Installation is the reverse of removal (haha).

I agree that if you can just drop it down in the vehicle to do the insulation without removing glass, I would do that instead (especially since you aren't replacing it).

Keep in mind that the sedan already has roof insulation. Under the hard white plastic liner is a dense mat of molded fiberglass.

You do need to remove the rear window if you want to take the roof liner out of the car. I think I heard of someone getting it out a door with the seats removed, but not sure if it is possible.

To remove the rear window: Remove the seatbelt mechanism covers on the back deck, remove the inside triangle window covers and then unplug the defroster wires on each side. Take a 3/8 inch rope and force it beween the rubber window seal and the frame on the inside. Work the rope under the seal around the whole window. Then try pushing out on one corner of the window. It should pop out of the frame. Then go outside the car and pull on the free corner.

But I would not do that if I were you. I would tilt the front seats flat and drop the liner on them. I am not sure how much room there is to put anything under the liner anyway so this all may be a waste of time.

To drop the headliner: Remove the grab handles and the dome light. Remove the sunvisors and the rear view mirror. Remove the three fasteners at the rear of the liner. I think you just turn them 90 degrees and they come out. The the liner should drop at the rear. Pull back and the front will drop (it just wedged into brackets).

Be carefull removing the rear view mirror. Don't try to pry the plastic cover off unless you want to break it(I learned this the hard way). It comes off with the mirror. It is a ball and socket, so it should come off with a hard pull. It does not always go smoothly. The last time I tried it I ripped the socket out of the roof with the ball.

In the wagon, the side and rear windows are held in only by their rubber gaskets. You remove each of them by lying down inside the wagon and using one of your well-shod feet to push steadily on that window, with slowly-increasing force, near one of the window's corners. Eventually, the gasket pops out at that corner and you can work your way around the perimeter, assuming you have someone out there to catch the window when it comes completely free. Before doing that to the rear window, you disconnect the window-heat wires.

No guarantee that that technique would work without breakage on a sedan rear window, but I have found the automobile window glass I have dealt with to far to be remarkably strong.

Reinstalling such windows is relatively easy, using a cord in the gasket slot to pull the gasket (and therefore the window) in over the lip of the window frame. Again , you need someone outside to hold it while you work the cord around the perimeter of the gasket. That technique is covered in detail elsewhere.

But if you can find a way to do the insulation job without removing the window, that would be my choice.
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jds

It might be worth your while to visit your local glass shop and have them give you an estimate for re and re of the glass. they should be able to keep it in one piece for you.