For 1990-2009 cars

Warning: Refer to Glass and Sheet Metal Handling Warning in the Preface section.

Note: Remove all but approximately 2 mm (3/64 in) of the existing bead of urethane adhesive from the pinch-weld flange.

1. Remove all mounds or loose pieces of urethane adhesive from the pinch-weld area.
2. If the original window is being reused, remove all but a thin film of the existing urethane adhesive from the window surface by using a clean utility knife or razor blade scraper.
3. Inspect the following components for the causes of a broken window:

• | The flange of the window opening

• | The window reveal molding

4. Inspect for any of the following problems in order to help prevent future breakage of the window.

• | High weld

• | Solder spots on the pinch-weld

• | 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 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/EPPG 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:

5.1. | Clear all broken glasses off the front hood, seat, floor, and defroster pipe.

5.2. | Use a fluff free cloth immersed into a 50/50 (by volume) of isopropyl alcohol and water solution to clean the inner surface edge of window glass.

Warning: Refer to Window Retention Warning in the Preface section.

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 (1) 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 (1).
9. Allow the pinch-weld primer to dry for approximately 10 minutes.

Note: Do not use spacers when installing a windshield. The stress caused by the spacers may damage the windshield.

10. Install the windshield (1) and the VIN plate filler strip, if equipped.

Note: When installing spacers (2) and/or blocks (3) space them equally around the quarter window, back window or the liftgate window (1) to aid in the height set, if equipped.

11. Install the window to the vehicle.
12. Install the new windshield acoustic strip (1) to the windshield (2), if equipped or damaged.

The acoustic strip aids in reducing noise.

13. If installing a new window reveal molding, start in the center and work toward each end pressing firmly into place.
14. With the aid of an assistant, dry fit the window (1) to the opening in order to determine the correct position.
15. Use masking tape in order to mark the locations (1) of the window (2) in the opening.
16. 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 kind of primer will dry immediately, and uneven application may pollute visible area of the window glass.

17. 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.

Wipe the priming area clean immediately by using a clean fluff free cloth.

18. Apply the second layer of glass protective agent (transparent #1) on the same position of the glass.

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.

19. Shake the glass primer (black #2) for at least 1 minute.
20. Using a new dauber, apply glass primer (black #2) to the same area (2) as that of glass protective agent (transparent #1)
21. Allow the glass primer to dry for approximately 10 minutes.
22. Cut the applicator nozzle in order to provide a bead of 12.7 mm (1/2 in) wide and 12.7 mm (1/2 in) high.
23. Use a cartidge-type caulking gun in order to apply a smooth, continuous bead of urethane adhesive.
24. Use the edge of the window 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 window (3).
25. With the aid of an assistant, place the window in the opening. If installing a windshield, place the windshield on the lower supports (2), if equipped.
26. Align the masking tape (1) lines on the window (2) and the body.
27. Press the window firmly into place.
28. Tape the window to the body in order to minimize movement until the urethane adhesive cures.
29. Clean any excess urethane adhesive from the body.

Note: Do not direct a hard stream of high pressure water to the freshly applied urethane adhesive.

30. Use a soft spray of warm water in order to immediately water leak test the window.
31. Inspect the window for leaks.
32. If any leaks are found, use a plastic paddle in order to apply extra urethane adhesive at the leak point.
33. 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.
34. 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.

35. Complete the window installation.