Chevrolet Sonic manuals

Chevrolet Sonic Repair Manual: Windshield Replacement

Special Tools

For equivalent regional tools, refer to Special Tools.

Removal Procedure
  1. Open the hood.
  2. Remove the windshield wiper arms. Refer to Windshield Wiper Arm Replacement.
  3. Remove the air inlet grille. Refer to Air Inlet Grille Panel Replacement.
  4. Remove the inside rearview mirror. Refer to Inside Rearview Mirror Replacement.
  5. Remove the interior windshield garnish moldings. Refer to Windshield Side Garnish Molding Replacement.
  6. Warning:

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

  7. Cover to protect the following parts from broken glass:
  • Upper dash pad
  • Defroster outlets and A/C outlets
  • Seats and carpeting

Warning:

Refer to Glass and Sheet Metal Handling Warning.

Note:

Before cutting out a stationary window, apply a double layer of masking tape around the perimeter of the painted surfaces and the interior trim.

  • Using the appropriate tool, carefully cut the windshield reveal molding?€‰(1) in order to access the auto-adhesive bead. Refer to Windshield Upper Reveal Molding Replacement.


  • Note:

    Keep the cutting edge of the appropriate tool against the window. There are window locating pins, one in each upper corner of the window. Use care Not to remove or cut them off when removing the window. If the window locator pins are cut, it will be necessary to tape the window in place.

  • This will allow the auto-adhesive to be separated from the window.
    • Leave a base of auto-adhesive on the pinchweld flange.
    • The only suitable lubrication is clean water.
    • Use BO-24402-A Glass Sealant Remover (Cold Knife).
    • BO-39032 Stationary Glass Removal Tool, or equivalent in order to remove the window.


  • Use the appropraite tool to remove the bottom of the window from the auto-adhesive. Keep the cutting edge of the tool against the window. Do this from inside the vehicle.

  • With an assistant, remove the window?€‰(2) from the vehicle. Check that the retainers?€‰(1) are still attached to the window before installing.
  • Installation Procedure
    1. Install the windshield into the opening. Refer to Adhesive Installation of Windshields.
    2. Install the rearview mirror. Refer to Inside Rearview Mirror Replacement.
    3. Install the interior windshield garnish moldings. Refer to Windshield Side Garnish Molding Replacement.
    4. Install the air inlet grille. Refer to Air Inlet Grille Panel Replacement.
    5. Install the windshield wipers arms. Refer to Windshield Wiper Arm Replacement.
    6. Remove the double layer of masking tape around the perimeter of the painted surfaces and the interior trim.
    7. Close the hood.
    Windshield Outside Moisture Sensor Cover Replacement
    Windshield Outside Moisture Sensor Cover Replacement Callout Component Name 1 Windshield Outside Moisture Sensor Cover ...

    Windshield Side Garnish Molding Replacement
    Windshield Side Garnish Molding Replacement Callout Component Name Preliminary Procedures Disable the SIR system, if equipped. ...

    Other materials:

    Front Seat Belt Buckle Replacement
    Front Seat Belt Buckle Replacement Callout Component Name Preliminary Procedures Remove the front seat. Refer to Driver or Passenger Seat Removal and Installation. 1 Driver or Passenger Seat Bel ...

    Wheel Drive Shaft Inner Joint Inspection
    Inspection Procedure Remove the front wheel drive shaft inner joint and boot. Refer to Front Wheel Drive Shaft Replacement. Remove the wheel drive shaft tripod bushing (1) from the tripod housing (3). Remove the wheel drive shaft tripod housi ...

    New Vehicle Break-In
    Notice: The vehicle does not need an elaborate break-in. But it will perform better in the long run if you follow these guidelines: Do not drive at any one constant speed, fast or slow, for the first 805 km (500 mi). Do not make full-throttle starts. Avoid downshifting t ...

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