Windshield

1. Use a urethane adhesive systems which meet GM Specification GM 3651G
Warning: Refer to Glass and Sheet Metal Handling Warning.

2. Remove all mounds or loose pieces of urethane adhesive from the pinch-weld area.
3. If the original window is being reused, remove all but approximately 2 mm (3/64 in) of the existing bead of urethane adhesive from the pinch-weld flange by using a clean utility knife or razor blade scraper.
4. Inspect for any of the following problems in order to help prevent future breakage of the window:
• High weld
• Solder spots on the pinchweld
• Hardened sealer
• Any other obstruction or irregularity in the pinch-weld flange
Note: If corrosion of the pinch-weld flange is present or if sheet metal repairs or replacements are required, the pinch-weld 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 DE15®, DuPont  2610®, Sherwin-Williams PSE 4600 and NP70® and Martin-Semour 5120 and 5130® PPG DP90LF SPIES/ HECKER 3688/8590 – 3688/5150 – 4070/5090 STANDOX 11158/13320 – 14653/14980 products are approved for this application.

5. After repairing the opening as indicated, perform the following steps:
1. Remove all traces of broken glass from the outer cowl panel, seats, floor and defroster ducts.
2. Clean around the edge of the inside surface of the window with a 50/50 mixture of isopropyl alcohol and water by volume on a dampened lint free cloth.
Warning: Refer to Window Retention Warning.

6. Verify all primers and urethane adhesive are within expiration dates.
Warning: 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.

Note: Do not apply the black #3 primer to the existing bead of the urethane adhesive on the pinch-weld flange. Apply the primer only to nicks, scratches or the primed surfaces.

7. Shake the pinch-weld primer black #3 for at least 1 minute.
8. Use a new dauber in order to apply the primer to the surface of the pinch-weld flange.
9. Allow the pinch-weld primer to dry for approximately 10 minutes.
10. With the aid of an assistant, dry fit the window (1) to the opening in order to determine the correct position.
    
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11. Use masking tape in order to mark the locations (1) of the window (2) in the opening.
    
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12. Cut the masking tape in the center and remove the window from the opening.
Note: Use care when applying glass prep clear #1 on the window. This primer dries almost instantly, and may stain the viewing area of the window if not applied evenly.

13. Use a new dauber in order to apply glass prep clear #1 to the area approximately 10–16 mm (3/8–5/8 in) around the entire perimeter of the window inner surface.
    Immediately wipe the glass primed area using a clean, lint-free cloth.
    
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14. Apply a second coat of the glass prep clear #1 to the same area of the glass.
    
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Note: The glass primer black #2 is effective up to 8 hours after applying it to the glass. The primed surface of the glass must be kept clean.

15. Shake the glass primer black #2 for at least 1 minute.
    
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16. Use a new dauber in order to apply the glass primer black #2 to the same areas (2) that glass prep clear #1 was applied.
17. Allow the glass primer to dry for approximately 10 minutes.
18. Cut the applicator nozzle in order to provide a bead of 8 mm (0.316 in) wide and 12.7 mm (1/2 in) high.
    
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19. Use a cartridge-type caulking gun in order to apply a smooth, continuous bead of urethane adhesive.
    
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20. Use the edge of the window as a guide for the nozzle in order to apply the urethane adhesive (1) to the inner surface of the window (3).
    
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21. Align the masking tape (1) lines on the window (2) and the body.
    
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22. Press the window firmly into place.
    
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23. Tape the window to the body in order to minimize movement until the urethane adhesive cures.
24. Clean any excess urethane adhesive from the body.
    
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Note: Do not direct a hard stream of high pressure water to the freshly applied urethane adhesive.

25. Use a soft spray of warm water in order to immediately water test the window.
    
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26. Inspect the window for leaks.
27. If any leaks are found, use a plastic paddle in order to apply extra urethane adhesive at the leak point.
28. Retest the window for leaks.
Warning: 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.

29. Maintain the following conditions in order to properly cure the urethane adhesive:
• Partially lower a door window in order to prevent pressure buildups when closing doors before the urethane adhesive cures.
• Do not drive the vehicle until the urethane adhesive is cured. Refer to the above curing times.
• Do not use compressed air in order to dry the urethane adhesive.
30. Complete the window installation.

Special Tools

• BO-24402-A - Glass Sealant Remover (Cold Knife) .
• BO-39032 - Stationary Glass Removal Tool , or equivalent in order to remove the window.
• Use a urethane adhesive systems which meet GM Specification GM 3651G

For equivalent regional tools, refer to Special Tools.

Removal Procedure

Note: Before cutting out a stationary window, apply a double layer of masking tape around the perimeter of the painted surfaces and the interior trim.

1. Open the hood.
2. Remove the windshield wiper arms. Refer to Windshield Wiper Arm Replacement.
3. Remove the air inlet grille. Refer to Air Inlet Grille Panel Replacement.
4. Remove the inside rearview mirror. Refer to Inside Rearview Mirror Replacement.
5. Remove the remote control door receiver antenna. Refer to Remote Function Actuator Module Replacement.
Warning: If broken glass falls into the defroster outlets, it can be blown into the passenger compartment and cause personal injury.

6. Cover to protect the following parts from broken glass:
• The upper dash pad
• The defroster outlets and A/C outlets
• The seats and carpeting
7. Remove the lower windshield supports from the cowl panel, if equipped.
Warning: 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.

8. Using the appropriate tool, carefully cut around the lace (1), start in the center working from side to side of the window to access the urethane adhesive bead, if equipped.
   
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Note: Keep the cutting edge of the tool against the window.

9. This will allow the urethane adhesive to be separated from the windshield.
   
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• Leave a base of urethane on the pinchweld flange.
• The only suitable lubrication is clear water.
• BO-24402-A - Glass Sealant Remover (Cold Knife) .
• BO-39032 - Stationary Glass Removal Tool , or equivalent in order to remove the window.
10. Remove the windshield (1) from the vehicle with the aid of an assistant (2).
    
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Installation Procedure

1. Install a stationary window into the opening. Refer to Adhesive Installation of Windshields.
2. Install the remote control door receiver antenna. Refer to Remote Function Actuator Module Replacement.
3. Install the inside rearview mirror. Refer to Inside Rearview Mirror Replacement.
4. Install the air inlet grille. Refer to Air Inlet Grille Panel Replacement.
5. Install the windshield wiper arms. Refer to Windshield Wiper Arm Replacement.
6. Close the hood.
7. Remove the double layer of masking tape from around the perimeter of the painted surfaces and the interior trim.

Special Tools

• S-0201964 - Bonded, Glass Removing Device
• Glass Handling Suction Cups
• Use an adhesive that is approved by GM

For equivalent regional tools, refer to Special Tools.

Removal Procedure

Note: Before cutting out a stationary window, apply a double layer of masking tape around the perimeter of the painted surfaces and the interior trim.

1. Open the hood.
2. Remove the windshield wiper arms and blades. Refer to Windshield Wiper Arm Replacement.
3. Remove the air inlet grille. Refer to Air Inlet Grille Panel Replacement.
4. Remove the windshield side garnish moldings. Refer to Windshield Side Garnish Molding Replacement.
5. Remove the sunshades. Refer to Sunshade Replacement.
6. Remove the inside rearview mirror. Refer to Inside Rearview Mirror Replacement.
7. Lower the front edge of the headliner this will allow the special tool S-0201964 - Bonded, Glass Removing Device to cut across the top of the window and not damage the headliner edge.
Warning: Refer to Defroster Outlet Warning.

8. Cover the following parts to protect from broken glass:
• Upper dash pad
• Defroster outlets and A/C outlets
• Seats and carpeting
Warning: Refer to Glass and Sheet Metal Handling Warning.

Note: If the original window is being reused the window lace is not serviceable.

9. Using the appropriate tool, carefully cut around the lace (1), start in the center working from side to side of the window to access the urethane adhesive bead, if equipped.
   
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10. Remove the window from the auto-adhesive as follows:
• Leave a base of urethane approximately 2 mm (0.078 in) on the pinch-weld flange.
• The only suitable lubrication is clear water.
• Use S-0201964 - Bonded, Glass Removing Device .
Note: Use care when removing the window not to cut off the locator pins in the left and right upper corners. If the locating pins are cut off it will be necessary to use masking tape to tape the window in place until the auto-adhesive cures.

11. Start the cut between the center of the windshield and the “A” pillar.
1. Do this from inside the vehicle, insert the tool S-0201964 - Bonded, Glass Removing Device  (1) between the “A” pillar and the windshield, thus perforating the adhesive.
2. Move the cutting wire along the outside edge of the window.
3. Remove the tool S-0201964 - Bonded, Glass Removing Device .
4. Do this from inside the vehicle, install the cutting wire special tool S-0201964 - Bonded, Glass Removing Device  (1).
5. Do this from outside the vehicle, install the cutting wire special tool S-0201964 - Bonded, Glass Removing Device  (2).
6. With an assistant, use the special tool S-0201964 - Bonded, Glass Removing Device  (1) to hold the cutting wire, pull it starting from the outside, back and forth releasing the window from the adhesive.
7. While cutting the window reposition the cutting wire and special tools, so as to cut the adhesive along the window completely.
12. Remove the windshield from the vehicle with an assistant, use the glass handling suction cups.
    
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Installation Procedure

1. If reusing or replacing the window, use the appropriate tool, remove the auto-adhesive bead on the window surface and pinch-weld flange to approximately 2 mm (0.078 in).
2. Clean the bonding area of the window.
   
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3. Apply bonded-glass primer and let dry per auto-adhesive instructions by the manufacturer’s.
   
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4. Apply the auto-adhesive primer-application (2) around the perimeter of the rear window (1) and let dry per auto-adhesive instructions by the manufacturer’s.
   
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5. Cut the applicator nozzle to provided a V cut to apply the auto-adhesive.
   
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Note: If the locating pins were cut off it will be necessary to tape the window in place until the auto-adhesive cures per auto-adhesive instructions by the manufacturer’s.

6. With an assistant, use the glass handling cups, align the windshield locating pins to the slots located in each corner of the pinch-weld flange. Lower the windshield to touch the auto-adhesive.
   
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7. Remove the glass handling cups.
8. Gently depress the windshield on the auto-adhesive bead until the windshield is seated 1 mm (0.039 in) below the roof.
   
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9. Use masking tape (1) to hold the window (2) in the position until the auto-adhesive completely cures.
   
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10. Make sure to observe the auto- adhesive curing time before releasing the vehicle per auto- instructions by the manufacturer’s.
Note: Following the auto-adhesive installation instructions, using nafta to remove any excess of auto-adhesive within 30 minutes, otherwise it will not be possible to remove the auto-adhesive excess unless using mechanical means.

11. Remove the double layer of masking tape around the perimeter of the painted surfaces and the interior trim.
Note: Do not direct a hard stream of high pressure water to the freshly applied auto-adhesive.

12. Use a soft spray of warm water in order to immediately water test the windshield.
    
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13. Inspect the windshield for leaks.
14. If any leaks are found, use a plastic paddle in order to apply extra auto-adhesive at the leak point.
15. Retest the windshield for leaks.
16. Maintain the following conditions in order to properly cure the auto-adhesive:
• Partially lower a door windshield in order to prevent pressure buildups when closing doors before the auto-adhesive cures.
• Do not use compressed air in order to dry the auto-adhesive.
17. Clean any excess auto-adhesive from the body.
    
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18. Install the air inlet grille. Refer to Air Inlet Grille Panel Replacement.
19. Install the windshield wipers arms and blades. Refer to Windshield Wiper Arm Replacement.
20. Install the windshield side garnish moldings. Refer to Windshield Side Garnish Molding Replacement.
21. Install front edge of the headliner.
22. Install the sunshades. Refer to Sunshade Replacement.
23. Install the inside rearview mirror. Refer to Inside Rearview Mirror Replacement.
24. Ensure that all electrical components operate properly.
25. Close the hood.