For 1990-2009 cars

### Removal Procedure

#### Tools Required

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

• | J 39032 Stationary Glass Removal Tool

• | Solvent for cleaning the window (use GM Glass Cleaner P/N 1050427 or equivalent

• | Household cartridge-type caulking gun

• | Commercial-type utility knife used to cut around the edge of the window

• | Rubber suction grips

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.

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

1. Apply masking tape to the painted surfaces around the windshield in order to prevent paint damage.
2. Remove the windshield wiper arms. Refer to Windshield Wiper Arm Replacement in Wipers/Washer Systems.
3. Remove the air inlet grille. Refer to Air Inlet Grille Panel Replacement in Body Front End.
4. Remove the defroster/rear of I/P panel. Refer to Instrument Panel Trim Pad Replacement in Instrument Panel, Gauges and Console.
5. Disconnect the antenna lead. Refer to Radio Antenna Cable Extension Cable Replacement

in Entertainment.

6. Remove the windshield reveal molding by grasping the lower corner of the windshield reveal molding with your hand and pulling the reveal molding away from the windshield while cutting the molding with a utility knife as needed.

Important: Keep the cutting edge of the tool against the windshield, this will allow the urethane adhesive to be separated from the windshield.

7. Use the J 24402-A and J 39032 to remove the windshield.
8. Remove the windshield from the vehicle with aid of an assistant.
9. The following components may reveal the causes of a broken windshield:

• | The flange of the windshield opening

• | The windshield reveal molding

• | The windshield

10. Look 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.

11. Inspect the condition of the windshield opening and the adhesive bead to determine which installation method should be used. Refer to the descriptions of short or extended method for guidelines.

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 present a clean primer only surface. 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 ® and PPG DP40 ®, or equivalent products are approved for this application.

12. After repairing the opening as indicated, perform the following steps:
13. Shake the pinchweld primer (#3 black) well.
14. Use a new dauber to apply the primer (1) to the primed surface of the flange in the bonding area.
15. Allow the primer to dry for approximately 10 minutes.

### Installation Procedure

1. 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.
2. Use masking tape (1) in order to mark the location of the windshield (2) in the opening.
3. Slit the masking tape at the top edge of the windshield.
4. Remove the windshield from the opening.
5. Place the windshield inside up on a clean, protected surface.
6. If the original window is being reused, remove all but a thin film of the existing urethane adhesive from the window surface using a utility knife or equivalent.
7. Clean the inside surface of the windshield with GM Glass Cleaner P/N 1050427 or equivalent.
8. If an extended method installation is being performed:

8.1. | Remove all but a thin film of the existing bead of adhesive from the pinchweld flange.

8.2. | It is not necessary to remove all traces of adhesive, but there should not be any mounds or loose pieces left.

8.3. | Shake the pinchweld primer (#3 black) well.

8.4. | Use a new dauber to apply the primer to any exposed painted surfaces (or scratches in the metal) of the flange in the bonding area.

8.5. | Allow the primer to dry for approximately 10 minutes.

9. Install a new windshield reveal molding to the edge of the windshield.
10. Install a new acoustic strip if needed.

Important: Use the following procedure:

11. Use care when applying the windshield prep (#1 clear) in order to prevent the windshield prep from running into the vision area of the windshield. This primer dries almost instantly and may stain the viewing area of the windshield.
12. If installing a new window:

12.1. | Use a new dauber, to apply the windshield prep (#1 clear) to the area approximately 10 mm to 16 mm (3/8 in 5/8 in) around the entire perimeter of the glass inner surface (reference the illustration of the primer/bonding areas).

12.2. | Apply the windshield prep (#1 clear) to any exposed edges of the window.

12.3. | Wipe the primed area immediately with a lint free cloth.

13. Shake the windshield primer (#2 black) well.

13.1. | Use a new dauber, to apply the windshield primer (#2 black) to the same areas that the windshield prep (#1 clear) was applied.

13.2. | Allow the primer to dry for approximately 6 minutes.

14. Cut the tip of the applicator nozzle as follows:

14.1. | If short method installation is being used, cut the tip to provide an adhesive bead of approximately 6.0 mm (1/4 in).

14.2. | If extended installation method is being used, cut the tip to provide an adhesive bead of approximately 12.7 mm (1/2 in) wide and 12.7 mm (1/2 in) high.

15. Use a cartridge type caulking gun, to apply a smooth continuous bead of urethane adhesive.
16. When using the short installation method, apply the urethane adhesive to the existing bead of urethane adhesive on the body.
17. When using the extended installation 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 (2) urethane adhesive to the inner surface of the (3) windshield.
18. Use rubber suction cups, and with the aid of a assistant, install the windshield into the opening.
19. Place the windshield on the lower supports if equipped.
20. Align the tape on the windshield and the body.
21. Press the windshield firmly into place.
22. Tape the windshield to body in order to minimize movement.

22.1. | Remove any excess urethane adhesive that may have squeezed out from the body.

22.2. | Use a soft spray of water in order to water test the windshield immediately.

22.3. | Warm or hot water is preferred in order to accelerate the cure of urethane adhesive.

22.4. | Do not direct a hard stream of high pressure water at fresh urethane adhesive.

Important: Inspect the windshield for leaks:

23. If any leaks are found, use a plastic paddle in order to apply extra urethane at the leak point.
24. Retest windshield for leaks.
25. Use the following procedure in order to properly cure the urethane adhesive.

• | Allow the vehicle to remain at room temperature of 22 °C ( 72° F) at 30% or less relative humidity.

• | Allow a minimum of ( 6 hours) for the moisture curing urethane adhesive.

• | Allow a minimum of ( 1 to 1 1/2 hours ) for the chemical curing urethane adhesive.

• | Partially lower a door window to prevent pressure build ups when closing doors prior to urethane adhesive cure.

• | Do not drive the vehicle until the urethane adhesive is cured.

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

26. Connect the antenna lead. Refer to Radio Antenna Cable Extension Cable Replacement in Entertainment.
27. Install the defroster/front of I/P panel. Refer to Instrument Panel Trim Pad Replacement in Instrument Panel, Gauges and Console.
28. Install the air inlet grille. Refer to Air Inlet Grille Panel Replacement in Body Front End.
29. Install the windshield wiper arms. Refer to Windshield Wiper Arm Replacement in Wiper/Washer System.
30. Remove the tape from the painted surfaces.