GM Prizm/Nova 1985-1993 Repair Guide

Windshield Glass

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REMOVAL & INSTALLATION



Extreme care must be taken when removing, installing or resealing a windshield. The windshield will crack if a stress in the wrong direction is exerted, even if the pressure is very slight. Undesirable stress on the windshield could take place during a number of operations. Damage could occur days after the repair has been completed, caused by the body of the vehicle flexing during normal vehicle operation, or during the removal of the outer moldings before any repair work has been done. This should be realized before the job of removing a windshield is undertaken.

REMOVAL & INSTALLATION



See Figures 1, 2 and 3

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the sunvisors, holders and the front assist grips.
  4.  
  5. Remove the inner rear view mirror.
  6.  
  7. Remove the front pillar garnishes.
  8.  
  9. Remove the hood, wiper arms and the cowl panel (louver).
  10.  
  11. Remove the hood weatherstrip by pulling upward. Take care not to tear the weatherstrip during removal.
  12.  
  13. Remove the retainer screws and the outside windshield molding.
  14.  
  15. Tape the end of a scraper and insert between the body and the upper windshield molding. Pry the molding upward and remove from the clips. Remove the molding from the vehicle.
  16.  
  17. Push piano wire from the interior of the vehicle outward and tie object to act as a handle to each end of the wire. Apply tape to the outer body surfaces to avoid scratching the finish. Cut the adhesive by pulling the piano wire, with the aid of a helper, around the windshield.
  18.  
  19. Carefully remove the glass from the vehicle.
  20.  

To install:
  1. Clean all adhesive off of the body of the vehicle. Clean all contact surfaces with an appropriate cleaner.
  2.  
  3. Remove old fasteners and replace with new.
  4.  
  5. Clean the removed glass of all adhesive and clean with an appropriate cleaner. Do not touch the contact area after cleaning.
  6.  
  7. Install new retainers to their original location. Install the spacer.
  8.  
  9. Position the glass onto the vehicle making sure all contacting parts of the glass are perfectly even and don't make contact with any fasteners.
  10.  
  11. Mark the position of the glass and remove.
  12.  
  13. Clean the contact surfaces of the glass.
  14.  
  15. Install the air dam with double tape making sure not to touch the glass.
  16.  
  17. Using a brush, coat the contact surface on the body with the appropriate primer according to manufactures instructions. Repeat the procedure using the appropriate compound on the glass.
  18.  
  19. Apply windshield adhesive to the contact points in a bead 0.39 inch (10mm) thick.
  20.  
  21. Install the glass aligning to the reference marks. Insure the correct sealing of the air dam. (lip curling downward and in the bead of sealer)
  22.  
  23. Apply a slight downward pressure on the glass to set into position. Using a spatula, apply adhesive to the outer rim of the glass.
  24.  
  25. Remove any excess sealer. Fasten glass securely until sealer sets. Water test once the sealer is fully dry.
  26.  
  27. If no leaks are present, carefully install the moldings, interior trim components, cowl panel, wiper arms and the hood.
  28.  
  29. Connect the negative battery cable.
  30.  



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Fig. Fig. 1: Windshield assembly and mouldings - 1985-88 Nova



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Fig. Fig. 2: Windshield assembly and mouldings - 1989-92 Prizm



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Fig. Fig. 3: Windshield assembly and mouldings - 1993 Prizm

 
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