Volume 12, Issue 4 - July/August 2010

The Cutting Edge
new car installations

2010 Chevrolet Corvette

by Jamie Browning

For vehicle and glass preparation, please refer to the Auto Glass Replacement Safety Standard (AGRSS/ANSI 002-2002) as well as your adhesive manufacturer’s recommendations. Inspect the windshield for defects and any contamination that may compromise the bonding of the adhesive. Also look for scratches or defects in the glass. Open the hood and lower the door glasses, and also remove the targa top or lower the convertible top.

Remove the wipers and label the driver and passenger side. Next remove the air inlet panel (cowl) by removing the seal along the front and the retaining screws. Then remove the rearview mirror, noting there are two different types, depending on the vehicle’s options. One is held in place with a T-20 torx screw and the other is removed by rotating the mirror counter clockwise until you hear a “click,” then slide the mirror off of the bracket.

Next, you want to remove the windshield weatherstrip by removing the left and right screws at the top corners of the windshield frame. Remove the four small push pins located at the bottom of the A-pillars. Carefully remove the weatherstrip and set aside for reinstall if you are not replacing it with a new one.

Remove the left and right side reveal mouldings by removing the four screws and remove the mouldings with the appliqué at the same time. Remove the left- and right-side garnish mouldings and the retaining clips.

Remove the four rearmost screws on the top of the fender to the wheelhouse. This allows extra room for working around the fender and General Motors (GM) recommends that you perform this step.

The windshield now can safely be removed using a cold knife, power tool or wire. GM approves only water as a cut-out lubricant if your adhesive manufacturer does not have one.

3. Preparing for the New Windshield:
Trim the existing urethane bead to 1 to 2 millimeters in height. Use your adhesive manufacturer’s pinchweld primer to prime all scratches and inspect the area for any conditions that might compromise the installation. Allow for proper drying time for the pinchweld primer and also remember to shake all primers for the correct length of time according to manufactures recommendations. Note that only the full-cut method is approved by GM and AGRSS.

4. Placement of the New Windshield:
Dry-fit the new windshield and mark it to ensure correct placement. Prepare the glass according to your adhesive manufacturer’s recommendations, apply the adhesive and install the windshield. Make sure the deck height is correct and the marks on the glass line up with those on the body that were applied during the dry-set.

5. Finishing Touches:
Install the left and right reveal side mouldings with new foam sealing tape if you are reusing the same ones. Extend the foam sealing tape 2 millimeters past each end of the moulding. Tighten the screws to 16 lb. in. (1.8 Newton meters) (nm) of torque. Next install the weatherstrip by applying a bead of sealant 3 inches or 75 mm beyond the roof latches on the header part of the windshield frame. Apply sealant at the top of the side mouldings and replace the two-sided tape on the weatherstrip, if reusing the weatherstrip, and tighten the two screws to 30 lb. in. (3.4 nm) of torque. Make sure to install the weatherstrip from the top center, working your way to the sides. Install the four fender mounting screws and tighten them to 17 lb. in. (1.9 nm of torque). Install the air inlet panel (cowl) and the rubber seal; then tighten the two screws to 27 lb. in. (3 nm) of torque. Install the wiper arms noting the driver and passenger side. Hold the wiper blade tip on the alignment marks on the windshield while you tighten the wiper nuts to 18 lb. ft (25 nm). Next install the rearview mirror; if it is equipped with a screw, tighten the screw to 13 lb. in. (1.5 nm) and connect the wiring on the back. If the mirror is attached with the twist-on style, be careful not to pull rearward on it, as this may cause the mirror or windshield to break. Center the bottom of the mirror to the bracket and rotate the mirror until a click is heard, so that you know the mirror is fully seated.

Finally check for any leaks and inform the vehicle owner of the safe drive-away time according to your adhesive manufacturer’s recommendations. Also be sure to record all lot numbers and the DOT number.

Jamie Browning was the winner of the 2009 Pilkington Classic Auto Glass Technician Olympics. He has more than 17 years’ experience in the industry. Mr. Browning’s opinions are solely his own and not necessarily those of this magazine.

© Copyright 2010 Key Communications Inc. All rights reserved.
No reproduction of any type without expressed written permission.