Volume 15, Issue 5- September/October 2013

The Cutting Edge
new car installations

2012 Chevy Volt
by Jamie Browning

1. Getting Started:
For vehicle and glass preparations please refer to ANSI/AGSC 002-2002 as well as your adhesive manufacturer’s recommendations.

If the vehicle is equipped with an electrochromic mirror or rain sensor, make sure the ignition is off. Using a plastic trim removal tool, slide the wire cover up and remove. Loosen the T20 screw and slide the mirror upward to remove and unplug the harness. To remove the A-pillar covers, remove the cover in the area where is says “airbag” at the top of the cover. Next remove the small bolt that holds the cover to the A-pillar and gently pull the cover away from the body releasing the clips. Next move to the outside of the car to remover the wipers. This is accomplished by removing the plastic wiper nut cover carefully and setting them aside. Remove the 14 mm wiper nuts and gently press on the joint in the middle of the arm to aid in releasing it.

To remove the cowl panel, gently remove the rubber hood weatherstripping running the length of the cowl. Next remove the cowl panel extensions and the six plastic push-pin clips. Use a plastic tool to release the moulding holding the cowl to the windshield and lift and slide the cowl up and away from the hood not toward the engine.

2. Removing the Windshield
For the sides and top of the windshield, a cold knife or power tool can be used as well as wire. For the bottom, a power tool or wire can be used. Note: If the new windshield does not have the lower retainer pre-installed, you will need to reuse the old one.

3. Preparing for the New Windshield
Trim the existing urethane bead, leaving it 1 to 2 mm in height. Use your adhesive manufacturer’s pinchweld primer to prime all scratches, if any exist, and allow to dry according to your adhesive manufacturer’s recommendations. Please note that only the full-cut method is permitted by the ANSI/AGSC 002-2002 Standard.

4. Placement of the New Windshield
Dry-fit the new windshield and mark it properly to ensure the correct setting procedure. Cut the urethane tip to provide a bead that is 12.7-mm high and 12.7-mm wide. Make sure the deck height is correct and the markings on the windshield line up with those on the body that were applied during the dry set.

5. Finishing Touches
Install the cowl in reverse order making sure there is a positive connection between the cowl and the windshield moulding.

To install the wipers position them on the small clear circles on the windshield and hold the arm in place while torqueing the nuts to 42 Nm (31 lb ft). Install the A-pillar covers noting the tabs have to be installed before the retainers. Press the cover into place, tighten the small bolt and install the bolt cover. Install the mirror in reverse order and torque the retaining screw to 1.8 Nm (16 lb in).

Be sure to check the rain sensor and wiper operation before returning the vehicle to the owner. Check for any leaks and be sure to inform the vehicle owner of the safe drive-away time, according to the adhesive manufacturer. Also be sure to record all lot numbers from the adhesive, VIN number and primers as well as the DOT number from the windshield.

Jamie Browning was the gold medalist in the 2009 Auto Glass Technician Olympics. He has more than 17 years of experience in the industry.


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