Windshield Replacement
Windshield Replacement
Tools Required
* J 24402-A Glass Sealant Remover (Cold Knife)
* J 39032 Stationary Glass Removal Tool
* J 34940 Rivet Gun
* Urethane Adhesive Kit or Equivalent
* Isopropyl Alcohol or Equivalent
* Cartridge-type Caulking Gun
* Commercial-type Utility Knife
* Razor Blade Scraper
* Suction Cups
* Plastic Paddle
Removal Procedure
1. Open the hood.
2. Lower the door windows.
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.
3. Remove the windshield wiper arms.
4. Remove the roof lift off panel (coupe) or lower the folding top (convertible).
5. Remove the hood air inlet screen seal.
6. Remove the air inlet screen panel.
7. Mark the location of the lower windshield supports with a grease pencil or tape.
8. Remove the lower windshield supports.
9. Remove the rearview mirror.
Caution: If broken glass falls into the defroster outlets, it can be blown into the passenger compartment and cause personal injury.
10. Cover the defroster grille outlets and interior as needed.
11. Remove the windshield weather-strip.
12. Remove the windshield side reveal moldings.
13. Remove the windshield side garnish moldings and retainer clips from the windshield frame
14. Remove the 4 rearmost screws that attach the top of the fender to the wheelhouse.
15. Reposition the top of the fender for tool access.
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.
Important: Tape or otherwise protect the fender from the cutting tool.
Keep the cutting edge of the tool against the windshield. This will allow the urethane adhesive to be separated from the windshield. Leave a base of urethane on the pinchweld flange. The only suitable lubrication is clear water.
16. Use the J 24402-A or J 39032 in order to remove the windshield.
17. Remove the windshield from the vehicle with the aid of an assistant.
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 windshield:
* The flange of the windshield opening
* The windshield reveal molding
3. Inspect for any of the following problems in order to help prevent future breakage of the windshield:
* High weld
* Solder spots
* Hardened spot weld sealer
* Any other obstruction or irregularity in the pinchweld flange
Important: If corrosion of the pinchweld flange is present, or if sheet metal repairs or replacements are required, the pinchweld flange must be refinished in order to restore the bonding area strength. If paint repairs are required, mask the flange bonding area prior to applying the color coat in order to provide a clean primer only surface. Materials such as BASF DE17(R), DuPont 2610(R), Sherwin-Williams PSE 4600 and NP70(R) and Martin-Semour 5120 and 5130(R) products are approved for this application.
4. After repairing the opening as indicated, perform the following steps:
1. Inspect the condition of the windshield opening and the adhesive bead to determine which installation method should be used.
2. Remove no more of the urethane adhesive from the pinchweld than necessary in order to maintain the original shape. This will ensure the proper clearance between the windshield and the pinchweld flange.
3. Remove all traces of broken glass from the outer cowl panel, seats, floor and defroster ducts.
4. Clean around the edge of the inside surface of the windshield with a 50/50 mixture of isopropyl alcohol and water by volume on a dampened lint free cloth.
5. After repairing the opening as indicated, shake the pinchweld primer (black #3) for at least 1 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.
6. Use a new dauber to apply the pinchweld primer (black #3) to the surface (1) of the bonding area on the body only.
7. Allow the primer to dry for approximately 10 minutes. Ensure that all nicks and scratches are covered.
8. Install the lower windshield supports.
9. If using extended method, install the spacers and the VIN plate filler strip.
Inspect the acoustic strip on the dash panel and replace if necessary.
10. With the aid of an assistant, dry fit the windshield in the opening in order to determine the correct way to position the windshield in the opening.
11. Carefully inspect the windshield overlap at the body pinch-weld and the retaining flanges all the way around the body opening.
The minimum overlap should be 5.0 mm (0.19 in).
12. Use masking tape in order to mark the location of the windshield in the opening.
13. Slit the masking tape at the top edge of the windshield.
14. With the aid of assistant and using suction cups remove the windshield from the opening.
15. Place the windshield inside up on a clean, protected surface.
16. If the original windshield is being reused remove all but a thin film of the existing urethane adhesive from the windshield surface using a clean utility knife or razor blade scraper.
Important: Do not remove all traces of the adhesive. Remove all mounds or loose pieces of urethane adhesive.
17. 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.
18. Clean around the edge of the inside surface of the windshield with a 50/50 mixture of isopropyl alcohol and water by volume on a dampened lint free cloth.
Important: Do not apply the (black #3) primer to the existing bead of the urethane adhesive. Apply the primer only to nicks, scratches or the primed surfaces.
19. Shake the pinchweld primer (black #3) for at least 1 minute.
20. Use a new dauber to apply the primer to the surface of the pinchweld flange.
21. Allow the pinchweld primer to dry for approximately 10 minutes.
Important: Use care when applying prep (clear #1) on the windshield. This primer dries almost instantly, and may stain the viewing area of the windshield if not applied evenly.
22. Use a new dauber in order to apply window prep (clear #1) to the area approximately 10-16 mm (3/8-5/8 in) around the entire perimeter of the window inner surface.
23. Apply a second coat of glass prep number (clear #1) to any exposed edges of the window.
24. Wipe the glass primed area immediately with a clean lint free cloth.
25. Shake glass primer (black #2) for at least 1 minute.
26. Use a new dauber in order to apply the primer (black #2) to the same areas that windshield prep (clear #1) was applied.
The glass primer (black #2) is good up to 8 hours after applying it to the glass. The primed surface of the glass must be kept clean.
27. Allow the primer to dry for approximately 10 minutes.
28. If using the short method, cut the tip of the applicator nozzle in order to provide a bead of 6.0 mm (1/4 in).
29. If using the extended method, cut the applicator nozzle in order to provide a bead of 12.7 mm (0.5 in) wide and 12.7 mm (0.5 in) high.
30. Use a cartridge type caulking gun to apply a smooth, continuous bead of urethane adhesive.
31. When using the short method, apply the urethane adhesive to the existing bead of urethane adhesive on the body.
32. When using the extended method, use the edge of the windshield 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 of the windshield (3).
If applying urethane adhesive to the inside edge of the windshield reveal molding (1) use the windshield reveal molding as a guide for the nozzle.
33. Place the windshield on the lower supports.
34. With the aid of an assistant, use the suction cups in order to install the windshield into the opening.
35. Align the tape lines on the windshield and the body.
36. Press the windshield firmly into place.
37. Tape the windshield to the body in order to minimize movement until the urethane adhesive cures.
38. Clean any excess urethane adhesive from the body.
Important: Do not direct a hard stream of high pressure water to the freshly applied urethane adhesive.
39. Use a soft spray of warm water in order to immediately water test the windshield.
40. Inspect the windshield for leaks.
41. If any leaks are found, use a plastic paddle in order to apply extra urethane adhesive at the leak point.
42. Retest the windshield 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.
The following conditions must be maintained to properly cure the urethane adhesive:
1. Partially lower a door window in order to prevent pressure buildups when closing doors before the urethane adhesive cures.
2. Do not drive the vehicle until the urethane adhesive is cured. Refer to the above curing times.
3. Do not use compressed air in order to dry the urethane adhesive.
43. Install the windshield side reveal moldings.
44. Install the windshield weather-strip.
Notice: Refer to Fastener Notice in Service Precautions.
45. Install the fender mounting screws.
Tighten the fender upper flange screws to 1.9 N.m (17 lb in).
46. Install the air inlet screen.
47. Install the air inlet screen seal.
48. Install the windshield wiper arms and washer hoses.
49. Install the windshield side garnish moldings.
50. Remove the rearview mirror.
51. Install the roof lift off panel (coupe) or raise and close the folding top (convertible).
52. Close the door windows.
53. Remove the protective coverings and tape from the vehicle.
54. Close the hood.