Cowl: Service and Repair

Windshield Lower Panel Replacement

Removal Procedure

Warning: Refer to Approved Equipment for Collision Repair Warning (Approved Equipment for Collision Repair Warning).

1. Disable the SIR system. Refer to SIR Disabling and Enabling (Service and Repair).
2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair).




3. Remove all related panels and components.
4. Repair as much of the damage as possible to factory specifications.
Warning: Refer to Foam Sound Deadeners Warning (Foam Sound Deadeners Warning).

5. Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair ().





Note: Do not damage any inner panels or reinforcements.

6. Locate and drill out all factory welds. Note the number and location of welds for installation of the windshield frame side panel.




7. Using a grinder or an equivalent tool, remove the silicon bronze welds at the upper windshield frame side panel and header location.




8. Remove the damaged windshield frame side panel.

Installation Procedure




1. Drill 8 mm (5/16 in) plug weld holes in the service part as necessary at the locations noted from the original windshield frame side panel.
2. Prepare all mating surfaces as necessary.
3. Apply GM-approved Weld-Thru coating or equivalent to all mating surfaces. Refer to Anti-Corrosion Treatment and Repair ().




4. Position the windshield frame side panel to the vehicle. Use 3-dimensional measuring equipment to ensure fit. Clamp the panel into place.





Note: Use either metal inert gas (MIG) or silicon bronze for welding the windshield frame side panel.

5. Using either a MIG or silicon bronze welder, weld the outer ends of the windshield frame side panel, duplicating the factory welds.




6. Using a MIG welder, plug weld as necessary, duplicating the factory welds.
7. Clean and prepare all welded surfaces.
8. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair ().
9. Paint the repair area. Refer to Paint Identification (Paint Identification).
10. Install all related panels and components.
11. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair).
12. Enable the SIR system. Refer to SIR Disabling and Enabling (Service and Repair).