For 1990-2009 cars

#### Tools Required

• | J 24402-A Glass Sealant Remover (Cold Knife)

• | J 39032

• | Urethane Adhesive Kit GM P/N 12346392 or equivalent

• | Isopropyl Alcohol or Equivalent

• | Cartridge-type Caulking Gun

• | Commercial-type Utility Knife

• | Razor Blade Scraper

• | Suction Cups

• | Plastic Paddle

### Removal Procedure

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.

1. Gently pry loose and remove the windshield side garnish moldings (1) from the vehicle.

Caution: If broken glass falls into the defroster outlets, it can be blown into the passenger compartment and cause personal injury.

2. Cover the defroster grille outlets as needed.
3. Remove the air inlet grille. Refer to Air Inlet Grille Panel Replacement in Body Front End.

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: The windshield reveal molding fills the cavities between the body and windshield and can not be reused if stretched or damaged.

4. Remove the windshield reveal molding.
5. Grasp the lower corner of the windshield reveal molding by hand and slowly pull the reveal molding away from the windshield.
6. If the windshield reveal molding will not release, use a utility knife in order to cut around the windshield in order to remove the windshield reveal molding.

Important: Keep the cutting edge of the tool against the windshield when removing 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.

7. Use the J 24402-A or J 39032 in order to remove the windshield.
8. Remove the windshield from the vehicle with aid of an assistant.
9. Unclip and remove the windshield glass support spacers from the windshield.

### Installation Procedure

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.

1. Inspect the following components for the causes of a broken windshield:

• | The flange of the windshield opening

• | The windshield reveal molding

• | The windshield

2. 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®, DuPont 2610®, Sherwin-Williams PSE 4600 and NP70® and Martin-Semour 5120 and 5130® products are approved for this application.

3. After repairing the opening as indicated, perform the following steps:

• | Inspect the condition of the windshield opening and the adhesive bead to determine which installation method should be used. Refer to Short Method Description or Extended Method Description for guidelines.

• | 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.

• | Remove all traces of broken glass from the outer cowl panel, seats, floor and defroster ducts.

• | 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.

After repairing the opening as indicated, perform the following:

1. 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.

2. Use a new dauber to apply the pinchweld primer (black #3) to the surface of the bonding area (1).
3. Allow the primer to dry for approximately 10 minutes. Ensure that all nicks and scratches are covered.
4. If using the extended method, install the spacers and the VIN plate filler strip.
5. Install the reveal molding to the edge of the windshield. If the original reveal molding is damaged, it must be replaced.
6. Install a new acoustic strip, if needed.
7. With the aid of an assistant, dry fit the windshield (2) in the opening in order to determine the correct way to position the windshield (2) in the opening.
8. Use masking tape (1) in order to mark the location of the windshield (2) in the opening.
9. Slit the masking tape (1) at the top edge of the windshield (2).
10. With the aid of assistant and using suction cups remove the windshield (2) from the opening.
11. Place the windshield (2) inside up on a clean, protected surface.
12. If the original windshield (2) is being reused, remove all but a thin film of the existing urethane adhesive (3) from the windshield surface by 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.

13. 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.
14. 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.

15. Shake the pinchweld primer (black #3) for at least 1 minute.
16. Use a new dauber to apply the primer to the surface of the pinchweld flange.
17. Allow the pinchweld primer to dry for approximately 10 minutes.

Important: Use care when applying the glass prep (clear #1) to the windshield. This primer dries almost instantly, and may stain the viewing area of the windshield if not applied evenly.

18. Use a new dauber in order to apply glass prep (clear #1) (2) to the area approximately 10-16 mm (3/8-5/8 in) around the entire perimeter (1,3) of the window inner surface.
19. Apply a second coat of the glass prep number (clear #1) to the same area (1,3) of the glass (4).
20. Wipe the primed glass area immediately with a clean lint free cloth.
21. Shake the glass primer (black #2) for at least 1 minute.
22. Use a new dauber in order to apply the glass primer (black #2) (2) to the same areas that glass 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.

23. Allow the glass primer to dry for approximately 10 minutes.
24. If using the short method, cut the tip of the applicator nozzle in order to provide a bead of 6.0 mm (0.25 in).
25. 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.
26. Use a cartridge type caulking gun to apply a smooth, continuous bead of urethane adhesive.
27. When using the short method, apply the urethane adhesive to the existing bead of urethane adhesive on the body.
28. When using the extended method, use the edge of the windshield window or the inside edge of the reveal molding as a guide for the nozzle in order to apply the urethane adhesive (2) to the inner surface of the windshield window (3).
29. Install the windshield glass support spacers to the windshield.
30. With the aid of assistant, use the suction cups in order to install the windshield (2) into the opening.
31. Align the tape lines (1) on the windshield (2) and the roof panel.
32. Press the windshield (2) firmly into place.
33. Tape the windshield (2) to the body in order to minimize movement until the urethane adhesive cures.
34. 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.

35. Use a soft spray of warm water in order to immediately watertest the windshield.
36. Inspect the windshield for leaks.
37. If any leaks are found, use a plastic paddle in order to apply extra urethane adhesive at the leak point.
38. Retest the windshield for leaks.
39. The following conditions must be maintained to properly cure the urethane:

39.1. | Allow the vehicle to remain at room temperature (21°C or 70°F) at 30 percent relative humidity.

| Caution: At least 24 hours are required for complete curing of repair material. The repair area should not be physically distrubed until after that time. Insufficient curing of urethane adhesive may allow unrestrained occupants to be ejected from the vehicle resulting in personal injury.

39.2. | Allow a minimum of 6 hours for the moisture curing urethane adhesive.

39.3. | Allow a minimum of 1 hour to 1 1/2 hours for the chemical curing urethane adhesive.

39.4. | Partially lower a door window in order to prevent pressure buildups when closing doors before the urethane adhesive cures.

39.5. | Do not drive the vehicle until the urethane adhesive is fully cured. Refer to the above curing times.

39.6. | Do not use compressed air in order to dry the urethane adhesive.

40. Install the air inlet grille. Refer to Air Inlet Grille Panel Replacement in Body Front End.
41. Install the windshield side garnish molding (1) to the vehicle. Ensure that the plastic retainers are fully engaged.

Caution: If broken glass falls into the defroster outlets, it can be blown into the passenger compartment and cause personal injury.

42. Remove the protective coverings and tape from the vehicle.