2003 GMC Envoy Vehicle Type: Four-Door Utility

NAGS® number*: DW01448 (Solar) (Rain Sensor), DW01447 (Solar), DW01446 (Rain Sensor), DW01445, DD09965-66 Door F/R-L (Solar), DD09967-68 Door R/R-L (Solar), DQ09978 Quarter L (Encap) (Solar) (W/On-Star), DQ09977 Quarter L (Ant) (Encap) (Solar), DQ09976 Quarter R (Ant) (Encap) (Solar), DV09971-72 Vent R/R-L (Encap) (Solar), DB09983 Back (Heated) (Solar), DB09982 Back (Solar)*. Installation time: , 2.2 hours; front door, 1.4 hours; back door, 1.4 hours; vent, 1.4 hours;

2003 GMC Envoy quarter, 2.3 hours; back glass, 1.4 hours. • Remove the left and right windshield moldings by remov- ing the weatherstrips in an outward motion. The molding is Technicians needed: One. attached with four No. 2 Phillips-head screws. The moldings Helpful tools or supplies: Rubber covers or molding have to be broken loose with an installation stick from both retention tape for the fenders or . sides; this is to avoid damaging the molding. This molding is a Watch for: Thin beads of urethane on the quarter glasses one-piece unit; when removing, be very careful not to damage and at the top corners of the windshield. Be sure to the paint. If you need to replace the side moldings, their clean or replace the rubber sleeves on the regulator replacement part numbers are OEM 15076977 for the right hardware that hold the glass on the door’s regulators. side and 15076976 for the left. • Remove the top molding by using an installation stick and *With permission from the National Auto Glass Specifications working it away from the glass and then pulling away from one 2003 Edition Fall Catalog and 2003 Fall Benchmark Calculator. corner to the other in small increments to avoid deforming the Contact NAGS at 800/551-4012 or visit www.nags.com. molding if reusing the original. Replacement part numbers are OEM 15095432 and Precision WFTD1448. • Remove the one-piece cowling by removing the three Windshield revealed plastic push-in fasteners with a small clip-removal tool, • Always wear eye and hand protection when working small hook tool or small flat-head screwdriver. There is one fasten- with glass. er on the driver side and two on the passenger side. • Make sure that you have the right glass and moldings and • Remove the two 10-millimeter nuts on the top part of the that the urethane systems you are about to use are current. cowling at each end. Windshield part number is a DW01448 GBN or GBY solar with • Remove the antenna and the two push-in plugs near the rain sensor or DW01447 GBN solar, DW01446 GBN or GBY (rain wiper post by lifting the cowl and using a panel remover to lift up sensor), and DW01445 GBN. The molding part numbers are OEM and disengage the push-in plugs. 15095432 and Precision WFTD1448. • If the windshield is broken, this can also be done from the • If you use a cold knife or power tool, remove the A trim top part of the cowling at the base of the windshield by using the panels as the windshield fits very close to the pinchweld. Remove windshield as a pivot point. the weatherstrip from the door jamb by pulling in a downward • Cover the hood and areas closest to the bottom of motion. Remove trim panels using an installation stick or a panel the windshield by using retention tape or a piece of rubber hose. remover. There are three fasteners: top, center and about 4 inches from the bottom of the panel near the dashboard. Removal • This is also a good time to remove the mirror from the wind- • Before beginning windshield removal, it is crucial to verify shield. Use a T-20 Torx mirror bracket wrench. that the new windshield is the correct one, and that the urethanes • Cover the front seats, the floorboards, the dash and the and primers are up to date. with a clean drop cloth or disposable plastic covers. • Make sure the cutting blades are sufficiently sharp. • Cover the roof with a hood cover. • Take a few minutes to remove any contaminant from the • Remove the windshield-wiper nut covers using an installation glass and pinchweld. This step will prevent contaminants from stick. The covers are very hard to remove; it might be a good idea making contact with the urethane. 3 to have replacements handy. • If using a cold knife, use a ⁄4-inch cold knife blade. Cut three • Remove the windshield-wiper nuts using a 14-millimeter sides and use a long knife or a power tool to cut the bottom of wrench or socket. the windshield. Be careful not to hit or cut the gravity stops; mark The wipers can sometimes be very hard to remove. To avoid stress- their locations with a marking pencil or retention tape. If you need ing the post, use a wiper puller to help take the wiper off the post. to replace the gravity stops, the OEM part number is 15061964.

24 AutoGlass™ • 2003–04 Field Guide 2003 GMC Envoy

• If you are trying to save the windshield, use an Equalizer with • Using a pinchweld scraper, remove as much of the original an 8-inch blade. urethane as the urethane manufacturer recommends. • When using any power tool, use plain water to lubricate the • Before removing the old urethane, make sure there are no cutting area. Spray the top and sides, then make your cuts. contaminants, and do not touch the pinchweld after you have • After cutting the sides and the top, place a Pumper in the prepped the area. top center of the windshield to open the cutting area on the bot- • Apply the pinchweld primer only to areas where it is needed, tom portion of the windshield. and follow the urethane manufacturer’s recommendations. Never use your head as a pushing device, as this could result in Be sure to allow preps and primers to dry as recommended by back and neck injuries. the urethane manufacturer. • Spray the bottom of the windshield at least 4-to-5 inches • Apply a triangular bead of urethane to the same path as the above the urethane on the glass so that the water will flow down freshly cut urethane on the pinchweld. into the urethane while you are making your final cut across the • Before cutting the V notch with a Top Notch tool, cut the tip bottom of the windshield. off the nozzle with a nozzle cutter. With the cut nozzle, measure 1 • Take the windshield out of the opening using a set of vacu- to the top of the roofline and add ⁄16 inch. Make a mark on the um cups. Lift the glass and place it on a windshield stand or a suit- nozzle at that point with a pen or marker. Notch the nozzle up to able workstation. the marked line. This will give you the appropriate triangular bead. • With the aid of the vacuum cups, lift the windshield from the Installation windshield stand or workstation. Reaching over, placing your • After cutting the windshield out, remove contaminants (such elbow on the setting pad on the hood, set the windshield on the as dirt, moisture and other debris) from the pinchweld. stop where the dry-fit mark has been made. Lower the driver side • This would be a good time to clean the dashboard. of the windshield onto the urethane and line up with the dry-fit • Be sure to dry fit the new glass to the opening. Make your mark; the windshield is now in place. marks with retention tape or a grease pencil. • The windshield is now ready to be decked. Press firmly to • Place the vacuum cups on the windshield in the appropriate ensure a good seal. location for a one-person set. • Before reinstalling the parts, take a few minutes to check for • For a driver-side setting of the windshield: While using glass leaks. Use a leak detector to go over the perimeter of the wind- handlers, place the setting elbow pad on the driver side of the shield. If you find a leak, apply a little more pressure to the spot, hood. Lift the windshield from the windshield stand using the vac- ensuring that the glass makes contact with the wet urethane. uum cups. • Reinstall the removed parts in reverse order. • Reaching over, place your elbow on the setting pad on the • Install the cowl cover and wipers. hood and set the windshield onto the stop. Place an alignment • Install the interior A pillar trim panels. mark on your side so that you can easily align the windshield • Allow the urethane to cure according to the urethane manu- when it is permanently installed. facturer’s recommended cure time before returning the vehicle to • With the windshield resting in the opening, go to the pas- the customer. senger side and make your dry-fit mark. To disregard the safe drive-away times that the urethane manu- • After you have adjusted on the passenger side to the correct facturer recommends could jeopardize the structural integrity of setting, walk back to the driver side, lift the glass and place it on a the and the safety of its passengers. windshield stand or a suitable workstation. • Reinstall the rearview mirror by sliding the mirror in a down- Front Door Glass ward motion until the base stops in place, then tighten the T-20 • Be sure you have the right glass; the door glass part number Torx screw. is DD09965-66 door F/R-L (Solar) GTN. • Follow the urethane manufacturer’s recommendations for • Using an installation stick, remove the beauty ring that covers installation. the interior door handle by releasing the two fasteners that hold • Clean the inside of the windshield using what the urethane the trim at the front of the beauty ring and the two at the rear of manufacturer recommends, and follow its steps. the ring. • Do not touch the windshield after cleaning it. • Remove the electrical accessory assembly with an installation • Remember to wear powder-free Nitrile gloves to keep from stick by prying gently at the front of the panel where one fastener coming in contact with any chemicals. sets and at the rear where there are two fasteners. • Apply the glass prep, following the urethane manufacturer’s • Remove the two 10-millimeter bolts—one at the rear end of recommendations. the armrest handle and the other beneath the electrical accessory • Do not touch the windshield after prepping it. assembly. • Apply the glass primer following the urethane manufacturer’s • Use either a magnetic socket or two-way tape to hold the recommendations. two 10-millimeter bolts onto the socket. This will keep the bolts • Do not touch the windshield after priming it. from falling when removing or reinstalling them. • Apply the molding to the windshield. The molding part num- • With a panel-removal tool, release the door trim panel held bers are OEM 15095432 and Precision WFTD1448. by eight plastic door-panel retainers. The retainers start about 5 • Be very careful not to touch the freshly primed area. inches down from the side and go all around the panel. The upper

AutoGlass™ • 2003–04 Field Guide 25 part of the panel, which looks like it is part of the frame, has one • Using an installation stick, remove the beauty ring that covers metal push-in fastener. the interior door handle by releasing the fastener that holds the • Slightly lift the door panel to disengage it from the interior trim at the front of the beauty ring and the two at the rear of weatherstrip on the underside of the panel. Remove it. the ring. • Press the electrical harness connectors and slide in a down- • Remove the electrical accessory assembly with an installation ward motion to disconnect the electrical accessory assembly. stick, prying gently at the front and rear of the panel. Fasteners • Set the door panel in a safe place. reside at each end of the panel. • Remove the interior weatherstrip in a gentle upward motion, • Remove the cover in the armrest handle cavity and the two using a panel remover. 7-millimeter bolts. • Peel back the plastic sound-and-weather barrier. • Using a panel-removal tool, release the door trim panel, • Lower the glass to align the mounting hardware to the open- which is held by eight door-panel retainers. The retainers start ing. Loosen the two 10-millimeter nuts. about 5 inches down from the side and go all around the panel. • Lift the glass out by lifting the backside of the glass first to • Slightly lift the door panel to disengage it from the interior disengage it from the carriage and the felt channel. weatherstrip on the underside of the panel. Remove the panel. • To replace the door glass, slip the glass back into the door in • Press the electrical harness connectors and slide in a down-

2003 GMC Envoy the same manner as it was removed. Make sure it is in the felt ward motion to disconnect the electrical accessory assembly. channel before reinstalling it onto the regulator carriage. • Set the door panel in a safe place. • Align the glass with the hardware and tighten the two 10- • Remove the interior weatherstrip in a gentle upward motion, millimeter nuts. using a panel remover. • Reconnect the electrical harness, sliding in an upward • Peel back the plastic sound-and-weather barrier. motion. • Lower the glass to align the mounting hardware to the open- • Be sure to check the operation of the glass before replacing ing. Loosen the two 10-millimeter nuts and leave them loosened. the panel to ensure that it operates properly. (It is not necessary to remove them completely.) • Disconnect the electrical harness by pressing the electrical • Lift the glass out by lifting the backside of the glass first to harness connector, sliding in a downward motion. disengage it from the carriage and remove it from the inside of • Reinstall the plastic sound-and-weather barrier. the felt channel. • Reinstall the interior weatherstrip. • Be sure that the panel fits onto the interior weatherstrip Vent Glass before sliding it back in place. • Be sure you have the right glass. The vent glass part numbers • Reconnect the electrical harness, sliding it upward. is DV09971-72 vent R/R-L (Encap)(Solar) GTY. • Lower the glass so that you can see that the panel is in the • Pull the channel felt away from the door frame. right place from the outside of the vehicle. Pull it onto the weath- • Remove the 10-millimeter bolt from the vent assembly. erstrip then push the panel back down. • Disengage the retainer at the top of the frame beneath the • Align the door panel retainers with the door retainers’ holes, rubber. Pull the vent glass assembly from the top of the vent in a then press or push the retainers back into place. rolling motion. Remove the vent glass assembly. • Reinstall the door handle beauty ring, the two 10-millimeter • Reinstall the vent glass assembly by sliding the vent into the bolts and the electrical accessory assembly by pushing the assem- opening and firmly pulling it into the door frame. Make sure the bly back in place. retainer is secured, then reinstall the 10-millimeter bolt. • Check the operation of the glass by rolling it up and down. • Reinstall the felt channel.

Back Door and Vent Glass Rear Door • Be sure that you have the right glass; the rear door glass part • To replace the rear door glass, slip the rear door glass back number is DD09967-68 door R/R-L (Solar) GTN. into the door in the same manner as it was removed. Be sure it is

Notes

26 AutoGlass™ • 2003–04 Field Guide 2003 GMC Envoy in the felt channel before reinstalling it onto the regulator carriage. • Do not touch the after prepping it. • Align the glass with the hardware and tighten the two 10- • Apply the glass primer following the urethane manufacturer’s millimeter nuts. recommendations. • Reconnect the electrical harness, sliding it upward. • Do not touch the quarter glass after priming it. • Be sure to check the operation of the glass before replacing • Using a pinchweld scraper, remove as much of the original the panel, to ensure that it operates properly. urethane as the urethane manufacturer recommends. • Press the electrical harness connectors and slide in a down- • Before removing the old urethane, make sure there are no ward motion to disconnect the electrical accessory assembly. contaminants, and be sure not to touch the pinchweld after you • Reinstall the plastic sound-and-weather barrier. have prepped the area. • Reinstall the interior weatherstrip. • Apply pinchweld primer only to areas where it is needed, and • Be sure that the panel fits onto the interior weatherstrip follow the urethane manufacturer’s recommendations. before sliding it back into place. Be sure to allow preps and primers to dry as recommended by • Reconnect the electrical harness, sliding it upward. the urethane manufacturer. • Lower the glass so that you can see that the panel is in the • Apply a triangular bead of urethane to the same path as the right place from the outside of the vehicle. Pull it onto the weath- freshly cut urethane on the pinchweld. erstrip, then push the panel back down. • Before cutting the V notch with a Top Notch tool, cut the • Align the door panel retainers with the door retainer holes, tip off the nozzle with a nozzle cutter. With the cut nozzle, 1 then press or push the retainers back into place. measure to the top of the roofline and add ⁄16 inch. Make a • Reinstall the two 7-millimeter bolts. Reinstall the cover in the mark on the nozzle at that point with a pen or marker. Notch armrest handle cavity. the nozzle up to the marked line. This will give you the appro- • Check the operation of the glass by rolling it up and down priate triangular bead. several times. • Place the vacuum cups on the quarter glass in the appropri- ate location. Quarter Glass • Lift the quarter glass from the windshield stand or a suitable • Be sure you have the right glass; quarter glass part numbers workstation using the vacuum cups. are DQ09978 quarter L (Encap)(Solar)(W/On-Star), DQ09977 quar- • Set the quarter glass in the opening. ter L (Ant)(Encap)(Solar) and DQ09976 quarter R • The quarter glass is now ready to be decked. Press firmly to (Ant)(Encap)(Solar) GTY or YPY. ensure a good seal. • Remove the T-50 Torx seat belt post. • Before reinstalling the parts, take a few minutes to check for • Remove the No. 2 Phillips-head screw. leaks. Use a leak detector to go over the perimeter of the quarter • Remove the two storage net posts at the rear of the panels. glass. If you do find a leak, apply a little more pressure to the spot, • Using a panel removal tool, release the quarter-panel trim and ensure that the glass makes contact with the wet urethane. held by nine quarter-panel retainers. The retainers start down from • Reinstall the removed parts in reverse order. the side and go across the panel and up the side to the rear. At • Allow the urethane to cure according to the urethane manu- the rear, there are three retainers that are closer to the glass at the facturer’s recommended cure time before returning the vehicle to rear part of the panel. the customer. • If you are trying to save the quarter glass, use an Equalizer with an 8-inch serrated blade. Adjust the depth of the blade so Back Glass 1 that only ⁄4 inch is exposed. • Be sure you have the right glass; back glass part numbers are • When using any power tool, use plain water to lubricate the DB09983 back window (Heated)(Solar), and DB09982 back win- cutting area. Spray the top, sides and bottom, then make your cuts. dow (Solar) GTY or YPY. • If the outer part of the encapsulation is glued to the side of • Remove the C clips that hold the gas lifters (sometimes called the vertical leg, use a small razor knife to cut it free from the ure- shocks or struts). Use a small-tipped screwdriver and slip them over thane. to the end of the lifter. • After cutting the quarter glass out, remove contaminants • Disconnect the two defroster electrical connectors, one on (such as dirt, moisture and other debris) from the pinchweld. each side, by sliding the connectors down. • Place vacuum cups on the quarter glass in the appropriate • Remove the two very small C clips from the hinge pins hold- location. ing the hardware that attaches the glass to the body. Make note • Follow the urethane manufacturer’s recommendation for of how the pins are positioned before you remove them to ensure installation. they are installed properly when replacing the glass. Slide the pins • Clean the inside of the quarter glass, using what the manu- in an outward motion. facturer recommends, and following its steps. • Reinstall the back glass and the removed parts in • Do not touch the quarter glass after cleaning it. reverse order. • Remember to wear powder-free Nitrile gloves to keep from • Check the operation of the back glass by opening and clos- coming in contact with any chemicals. ing it several times. • Apply the glass prep, following the urethane manufacturer’s — Gilbert R. Gutierrez, product sales director and senior recommendations. technical advisor, Equalizer Industries Inc., Round Rock, TX

AutoGlass™ • 2003–04 Field Guide 27