Windshield Replacement
REMOVAL PROCEDUREWindshield Replacement: Removal Procedure:
Tools Required
^ J 39040 Quarter Glass Remover
^ J 41993 Windshield Blade
^ Solvent for cleaning the edge of the window use GM Glass Cleaner P/N 1050427 or Isopropyl
^ Cartridge-type caulking gun
^ Commercial type razor knife for cutting around the edges of the windows.
^ Rubber suction cups.
CAUTION
^ When replacing stationary windows, Urethane Adhesive Kit GM P/N 12346284, or a urethane adhesive system meeting GM Specification GM365IM, must be used 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.
^ When working with any type of glass, use approved safety glasses and gloves to reduce the chance of personal injury
^ If broken glass falls into the defroster outlets, it can be blown into the passenger compartment and cause injuries. To help avoid personal injury cover the defroster outlets before replacing windows.
1. Mask off the area around the windshield to protect the paint and to protect the tops of the front fenders.
2. Open the hood.
3. Remove the hood sealing weather-strip from the air inlet grille panels.
4. Remove the windshield wiper arms and blades.
5. Remove the air inlet grille.
6. Remove the windshield wiper nozzle heater electrical connector located under the night side of the air inlet grille panel.
7. Tape both corners of the hood to prevent damage.
8. Tape both corners of the fenders to prevent damage.
9. Remove the hood.
10. Remove the windshield garnish molding.
11. Remove the inside rearview mirror (automatic memory).
12. Check the clearance of the headliner to the windshield.
13. Protect the headliner as necessary. Ensure the corners are protected.
14. Remove the sunshades.
15. Remove the sunroof selector knob, if equipped.
16. Remove two screw and sunroof actuator motor cover.
17. Remove the windshield reveal moldings from the reveal molding retainers.
18. Mask the area around the windshield to protect the painted surfaces and the area around the windshield to aid in the clean up after the windshield is installed.
19. Perform the following steps to cut out the windshield:
19.1. Use the J 39040 with the J 41993.
19.2. Keep the J41993 as close to the windshield as possible to prevent damage to the following components:
^ To prevent damage to the headliner.
^ To prevent damage to the painted surfaces.
20. Using suction cups and with the aid of a helper remove the windshield from the opening.
INSTALLATION PROCEDURE
Windshield Replacement: Installation Procedure:
1. Install windshield with the aid of a helper, dry fit the window in the opening to determine the correct position of the windshield by:
^ Position windshield in the opening.
^ Using masking tape, mark the location of the window in the opening.
^ Slit the masking tape at the window edge.
^ Remove window from the opening an place it inside up on a clean protected surface.
2. Clean the surface of the window to which urethane adhesive will contact (around edge of inside surface with a clean isopropyl dampened cloth, or with GM Window Cleaner P/N 1050427 or equivalent.
3. Repair the opening as indicated:
^ If the extended method is being used, shake pinchweld primer # 3 (black) well, and apply to any exposed painted surfaces (or scratches to bare metal) on the pinchweld flange. Allow to dry for 10 minutes.
^ If the short method is being used, DO NOT prime the existing bead of urethane on the body.
IMPORTANT: If corrosion of the pinchweld flange is present, or if sheet metal repays or replacements are required, the pinchweld flange must be reftnished to present a clean Primer Only surface.
If paint repairs are required, mask the flange bonding area (prior to applying the colour coat) to provide a clean Primer Only surface.
4. After repairing the opening as indicated, shake the pinchweld primer # 3 (black) well, and using a new dauber, apply to the primed surface of the flange in the bonding area. Allow to dry for 10 minutes.
5. If the original window is being reused, remove any existing urethane adhesive from the window edge and surface using a razor knife or equivalent.
6. If original reveal molding or new production type reveal molding is being used, install molding to window.
7. Install new acoustic strip on windshield, if necessary.
8. It the extended method is being used, apply a dam material, such as Norton Windshield Dam Replacement or equivalent, approximately 12 mm to 18 mm (1/2 inch to 5/8 inch), depending on the width of the pinchweld flange, from the outer edge of the window, around the perimeter of the window to control urethane squeeze out.
IMPORTANT: Care should be taken to prevent clear primer from running into the vision area of the window. This primer dries almost instantly, but may stain the viewing area of the window if not applied evenly.
Windshield Replacement: Installation Procedure:
9. Using a new dauber, apply glass prep # 1 (clear) for approximately 10 mm to 16 mm (3/8 to 5/8 inch) around the entire perimeter of the inner surface and any exposed edges of the window. Wipe dry with a clean cloth.
10. Shake window primer # 2 (black) well, and using a new dauber, apply primer to the same areas that window prepare 1 (clear) were applied to. Allow to dry for approximately 6 to 10 minutes.
Windshield Replacement: Installation Procedure:
11. Cut the tip of the application nozzle:
^ If the short method is being used, cut the tip of the application nozzle to provide a bead of approximately 4.5 mm (1/8 inch to 3/16 diameter.
^ If extended method is being used, cut the tip of the application nozzle at a 45°angle with a 13 mm (1/2 in) groove to provide a bead of approximately 8 mm (5/16 in) wide x 13 mm high (5/16 in x 1/2 in).
Windshield Replacement: Installation Procedure:
12. Using a cartridge type caulking gun, apply a smooth continuous bead of urethane adhesive;
12.1. Apply urethane adhesive to the existing bead of urethane adhesive on the body when using the short method.
12.2. Apply urethane adhesive to the edge of the window (or inside edge of the revealing molding in certain cases) as a guide for the nozzle, Apply urethane to the inner surface of the window, when using the extended method.
13. Install the bottom windshield reveal molding into the reveal molding retainers last because the air inlet grille panels fasten under the reveal molding.
14. Install the windshield reveal molding into the reveal molding retainers.
Windshield Replacement: Installation Procedure:
15. Using suction cups, and with the aid of a helper, position the windshield in the opening and align to the previously installed masking tape.
16. Press the window firmly into place until the reveal molding is flush with the surrounding sheet metal.
17. Tape the window to the body to minimize movement and clean up any urethane squeeze out from body.
18. Watertest the window immediately using a soft spray. Warm or hot water is preferred to accelerate the cure of the adhesive. DO NOT direct a hard stream of high pressure water at fresh urethane adhesive.
18.1. Refer to Water Hose Test in Waterleaks.
18.2. If leaks are found, apply extra urethane adhesive at leak point using a plastic paddle.
19. Install the remaining revealing moldings if necessary and remove protective tape and coverings.
IMPORTANT: Allow the vehicle to remain at room temperature (22 degrees Celsius/72 degrees Fahrenheit at 30% relative humidity) for a minimum of 6 hours.
Manually lower a door window to prevent pressure build ups when closing doors prior to urethane adhesive cure.
DO NOT DRIVE VEHICLE until urethane adhesive is cured (minimum of six hours at room temperature).
DO NOT USE COMPRESSED AIR to dry urethane adhesive.
20. Install the sunroof actuator motor cover and two screws.
21. Install the sunroof selector knob, if equipped.
22. Install the sunshades.
23. Install the inside rearview mirror (automatic memory).
24. Install the windshield garnish molding.
25. Install the hood.
26. Remove the tape from both corners of the hood.
27. Remove the tape from both corners of the fender.
26. Install the windshield wiper nozzle heater electrical connector under the right side air inlet grille panel.
29. Install the Air inlet grille panels.
30. Install the Windshield wiper arms and blades.
31. Install the hood sealing weatherstrip to the air inlet grille panels.
32. Close the hood.