Adhesive Installation of Stationary Windows. Chevrolet Malibu 2006

For 1990-2009 cars only

Makes 🢒 Chevrolet 🢒 2006 🢒 Malibu 🢒 Preface 🢒 Cautions and Notices 🢒 Adhesive Installation of Stationary Windows

Adhesive Installation of Stationary Windows Windshield

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

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

Remove all mounds or loose pieces of urethane adhesive from the pinch-weld area.
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.
Inspect the following components for the causes of a broken window:

•	The flange of the window opening

•	The window reveal molding

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

•

High weld

•	Solder spots

•	Hardened sealer

•	Any other obstruction or irregularity in the pinch-weld flange

Important: 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:

5.1.	Remove all traces of broken glass from the outer cowl panel, seats, floor and defroster ducts.

5.2.	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.

Caution: When replacing stationary windows, use Urethane Adhesive Kit GM P/N 12346392 (Canadian P/N 10952983), or a urethane adhesive system meeting GM Specification GM3651G, to maintain original installation integrity. Failure to use the urethane adhesive kit will result in poor retention of the window which may allow unrestrained occupants to be ejected from the vehicle resulting in personal injury.

Verify all primers and urethane adhesive are within expiration dates.

Caution: 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.

Important: 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.

Shake the pinch-weld primer black #3 for at least 1 minute.
Use a new dauber in order to apply the primer to the surface of the pinch-weld flange (1).
Allow the pinch-weld primer to dry for approximately 10 minutes.

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

The acoustic strip aids in reducing noise.

If the original windshield is being reused, and the windshield reveal molding is damaged or becomes detached, replace the windshield reveal molding. Refer to Windshield Reveal Molding Replacement .

With the aid of an assistant, dry fit the window (1) to the opening in order to determine the correct position.

If equipped, ensure that the windshield locator pins are positioned into the locator slots on the upper pinch-weld flange.

Using 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.

Important: Use care when applying glass prep clear #1 on the window. This primer dries almost instantly, and may stain the viewing area of the window if not applied evenly.

Use a new dauber in order to apply glass prep clear #1 to the area approximately 18 mm (0.71 in) around the entire perimeter of the window inner surface.

Immediately wipe the glass primed area using a clean, lint-free cloth.

Apply a second coat of the glass prep clear #1 to the same area of the glass.

Important: 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.

Shake the glass primer black #2 for at least 1 minute.
Use a new dauber in order to apply the glass primer black #2 to the same areas (2) that glass prep clear #1 was applied.
Allow the glass primer to dry for approximately 10 minutes.

Cut the applicator nozzle in order to provide a minimum urethane bead of 8 mm (0.31 in) wide and 16 mm (0.63 in) high.

Use a cartridge-type caulking gun in order to apply a smooth, continuous bead of urethane adhesive.

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).

With the aid of an assistant, place the window in the opening.

Align the masking tape (1) lines on the window (2) and the body.

Important: To prevent damage to the window due to objects impacting an exposed edge, upon installation, the window must rest 1 mm (0.040 in) below the surface of the sheet metal.

Press firmly around the entire periphery of the windshield in order to wet-out the urethane bead.
Tape the window to the body in order to minimize movement until the urethane adhesive cures.

Clean any excess urethane adhesive from the body.

Important: 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.

Caution: 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.

Adhesive Installation of Stationary Windows Rear Window

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

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

Remove all mounds or loose pieces of urethane adhesive from the pinch-weld area.
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.
Inspect the following components for the causes of a broken window:

•	The flange of the window opening

•	The window reveal molding

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

•

High weld

•	Solder spots

•	Hardened sealer

•	Any other obstruction or irregularity in the pinch-weld flange

After repairing the opening as indicated, perform the following steps:

5.1.	Remove all traces of broken glass from the outer cowl panel, seats, floor and defroster ducts.

5.2.	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.

Important: 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.

Shake the pinch-weld primer black #3 for at least 1 minute.
Use a new dauber in order to apply the primer to the surface of the pinch-weld flange (1).
Allow the pinch-weld primer to dry for approximately 10 minutes.
If the original window is being reused, and the window reveal moldings are damaged or becomes detached, replace the reveal moldings. Refer to Rear Window Reveal Molding Replacement .

With the aid of an assistant, dry fit the window (2) to the opening in order to determine the correct position.
Ensure that the locator pins (1) are positioned into the locator slots on the upper pinch-weld flange.

Use masking tape to mark the locations of the window in the opening.
Cut the masking in the center and remove the window from the opening.

Important: Use care when applying glass prep clear #1 on the window. This primer dries almost instantly, and may stain the viewing area of the window if not applied evenly.

Use a new dauber in order to apply glass prep clear #1 to the area approximately 18 mm (0.71 in) around the entire perimeter of the window inner surface.

Immediately wipe the glass primed area using a clean, lint-free cloth.

Apply a second coat of the glass prep clear #1 to the same area of the glass.

Important: 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.

Shake the glass primer black #2 for at least 1 minute.
Use a new dauber in order to apply the glass primer black #2 to the same areas (2) that glass prep clear #1 was applied.
Allow the glass primer to dry for approximately 10 minutes.

Cut the applicator nozzle in order to provide a minimum urethane bead of 8 mm (0.31 in) wide and 16 mm (0.63 in) high.

Use a cartridge-type caulking gun in order to apply a smooth, continuous bead of urethane adhesive.

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).

With the aid of an assistant, place the window in the opening.

Align the masking tape (1) lines on the window (2) and the body.

Important: To prevent damage to the window due to objects impacting an exposed edge, upon installation, the window must rest 1 mm (0.040 in) below the surface of the sheet metal.

Press firmly around the entire periphery of the window in order to wet-out the urethane bead.
Tape the window to the body in order to minimize movement until the urethane adhesive cures.

Clean any excess urethane adhesive from the body.

Important: 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.

Caution: 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.

Adhesive Installation of Stationary Windows Liftgate

Caution: When working with any type of glass or sheet metal with exposed or rough edges, wear approved safety glasses and gloves in order to reduce the chance of personal injury.

Important: Remove all but approximately 2 mm (0.078 in) of the existing bead of urethane adhesive from the pinch-weld flange.

Remove all mounds or loose pieces of urethane adhesive from the pinch-weld area.
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.
Inspect the following components for the causes of a broken window:

•	The flange of the window opening

•	The window reveal molding

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

•

High weld

•	Solder spots

•	Hardened sealer

•	Any other obstruction or irregularity in the pinch-weld flange

Important: 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 DE17®, 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:

5.1.	Remove all traces of broken glass from the seats, floor and/or defroster ducts, if applicable.

5.2.	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.

5.3.	Allow the isopropyl alcohol to dry completely before applying the primers.

Verify all primers and urethane adhesive are within expiration dates.

Important: Do not apply the black #3 primer to the existing bead of the urethane adhesive on the pinch-weld flange. Apply the primer only to nicks, scratches or the primed surfaces.

Shake the pinch-weld black #3 primer for at least 1 minute.
Use a new dauber in order to apply the primer to the surface of the pinch-weld flange.
Allow the pinch-weld primer to dry for approximately 10 minutes.
If the original window is being reused, and the window reveal moldings are damaged or become detached, replace the reveal moldings. Refer to Liftgate Window Reveal Molding Replacement .

With the aid of an assistant dry fit the window to the opening in order to determine the correct position.
Ensure that the window locator pins are positioned into the locator slots on the upper liftgate sheet metal.
Center the glass side to side into the liftgate opening.
Use masking tape in order to mark the locations of the liftgate window in the opening.
Cut the masking in the center. Remove the liftgate window from the opening.

Important: Use care when applying clear #1 glass prep on the window. This primer dries almost instantly, and may stain the viewing area of the window if not applied evenly.

Use a new dauber in order to apply clear #1 glass prep to the area approximately 18 mm (0.71 in) around the entire perimeter of the window inner surface.

Immediately wipe the glass primed area using a clean, lint-free cloth.

Apply a second coat of the glass prep clear #1 to the same area of the glass.

Important: The black #2 glass primer is effective up to 8 hours after applying it to the glass. The primed surface of the glass must be kept clean.

Shake the black #2 glass primer for at least 1 minute.
Use a new dauber in order to apply the black #2 glass primer to the same areas (2) that the clear #1 glass prep was applied.
Allow the glass primer to dry for approximately 10 minutes.

Cut the applicator nozzle in order to provide a minimum urethane bead of 8 mm (0.31 in) wide and 16 mm (0.63 in) high.

Important: The urethane adhesive bead must maintain a consistent height and width uniformity.

Use a cartridge-type caulking gun in order to apply a smooth, continuous bead of urethane adhesive.

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).

Important: The liftgate glass must be installed to the liftgate opening within 5 minutes after the urethane adhesive is dispensed.

With the aid of an assistant, position the window into the liftgate opening.
Align the masking tape on the liftgate window to the liftgate masking tape.

Important: To prevent damage to the window due to objects impacting an exposed edge, upon installation, the window must rest 1 mm (0.040 in) below the surface of the sheet metal.

Press firmly around the entire periphery of the liftgate window edge in order to wet-out the urethane adhesive bead.
Tape the window to the liftgate in order to minimize movement until the urethane adhesive cures.

Clean any excess urethane adhesive from the body by using VMP Naptha.
Clean any excess urethane adhesive from the interior trim by using Acrysol.

Important: 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.

Caution: 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.