Chevrolet Sonic Repair Manual: Adhesive Installation of Rear Windows
Warning:
Refer to Glass and Sheet Metal Handling Warning.
- Use a urethane adhesive systems which meet GM Specification GM?€‰3651G.
- Remove all mounds or loose pieces of urethane adhesive from the pinchweld
area.
- If the original window is being reused, remove all but approximately 2?€‰mm?€‰(3/64?€‰in)
of the existing bead of urethane adhesive from the pinchweld flange by using
a clean utility knife or razor blade scraper.
- Inspect for any of the following problems in order to help prevent future
breakage of the window:
- The flange of the window opening
- High weld
- Solder spots
- Hardened sealer
- Any other obstruction or irregularity in the pinchweld 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 strength. 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?€‰DE15?®, DuPont ?€‰2610?®,
Sherwin-Williams PSE?€‰4600 and NP70?® and Martin-Semour 5120 and 5130?® PPG?€‰DP90LF
SPIES/ HECKER?€‰3688/8590 ?€“ 3688/5150 ?€“ 4070/5090 STANDOX?€‰11158/13320
?€“ 14653/14980 products are approved for this application.
After repairing the opening as indicated, perform the following steps:
- Remove all traces of broken glass from the outer cowl panel, seats, floor
and defroster ducts.
- Clean around the edge of the inside surface of the window with a 50/50 mixture
of isopropyl alcohol and water by volume on a dampened lint free cloth.
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.
Apply the primer to the surface of the pinch-weld flange?€‰(1).
Allow the pinch-weld primer to dry per auto-adhesive instructions by the manufacturer?€™s.
Use masking tape in order to mark the locations?€‰(1) of the window?€‰(2) in
the opening.
Cut the masking tape in the center and remove the window from the opening.
Apply glass prep clear to the area approximately 10?€“16?€‰mm (3/8?€“5/8?€‰in)
around the entire perimeter of the window inner surface.
Immediately wipe the glass primed area using a clean, lint-free cloth.
Apply bonded-glass primer and let dry per auto-adhesive instructions by the
manufacturer?€™s.
Apply the auto-adhesive primer-application?€‰(2) around the perimeter of the
window?€‰(1) per auto-adhesive instructions by the manufacturer?€™s.
Apply the glass primer black to the same areas?€‰(2) that glass prep clear was
applied.
Allow the glass primer to dry per auto-adhesive instructions by the manufacturer?€™s.
Install the window reveal molding?€‰(1). Install the window reveal molding.
Refer to Rear Window Reveal Molding Replacement.
Use a cartridge-type caulking gun in order to apply a smooth, continuous bead.
Cut the applicator nozzle to provided a V cut to apply the auto-adhesive.
Use the edge of the window as a guide for the nozzle in order to apply the urethane
adhesive?€‰(1) to the inner surface of the window?€‰(3).
Note:
If the locating pins were cut off it will be necessary to tape
the window in place until the auto-adhesive cures per auto-adhesive instructions
by the manufacturer?€™s.
With an assistant, align the window locating pins?€‰(1) to the slots located
in each corner of the pinch-weld flange. Lower the window?€‰(2) to touch the auto-adhesive.
If the locating pins were damaged, align the masking tape?€‰(1) lines on the
window?€‰(2) and the body.
Gently depress the window on the auto-adhesive bead until the window reveal
molding is seated.
Tape the window to the body in order to minimize movement and until the auto-adhesive
cures per auto-adhesive instructions by the manufacturer?€™s.
Ensure all excess urethane adhesive is cleaned from the body before water test.
Note:
Do not direct a hard stream of high pressure water to the freshly
applied urethane adhesive.
Use a soft spray of warm water in order to immediately water test the window.
Inspect the window for leaks.
If any leaks are found, use a plastic paddle in order to apply extra urethane
adhesive at the leak point.
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.
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.
Complete the window installation.
Warning: Refer to Glass and Sheet Metal Handling Warning.
Use a urethane adhesive systems which meet GM Specification GM?€‰3651G.
Remove all mounds or loose pieces of urethane ad ...
Warning: Refer to Glass and Sheet Metal Handling Warning.
Use a urethane adhesive systems which meet GM Specification GM?€‰3651G.
Remove all mounds or loose pieces of urethane ad ...
Other materials:
Backup Lamp Switch Replacement
Removal Procedure
Disconnect the electrical connector from the backup lamp switch?€‰(1).
Remove the backup lamp switch?€‰(1) from the transmission.
Remove and DISCARD the backup lamp switch washer from the backup lamp
switch.
Installation Proc ...
Outside Rearview Mirror Remote Control Switch Replacement
Outside Rearview Mirror Remote Control Switch Replacement
Callout
Component Name
Preliminary Procedure
Remove the front side door widow switch bezel. Refer to Front Side Door
Window Switch Bezel Replacement.
...
Control Valve Body Assembly Assemble (Gen 2)
Control Valve Body Assembly Assemble
Callout
Component Name
1
Valve Body Ball Check Valve (Qty: 6)
2
Valve Channel Plate
3
Control Valve Body Bolt ...
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