1. Preparation:
* Safety First: Wear safety glasses and gloves. The glass is sharp!
* Gather Tools: You'll need a variety of tools, including:
* Panel removal tools (plastic pry bars to avoid scratching)
* Screwdrivers (Phillips and possibly flathead)
* Glass suction cups (at least two large ones)
* Utility knife or razor blade (to carefully cut old sealant)
* Putty knife (for removing old sealant)
* Clean rags or shop towels
* New window glass (ensure it's the correct one for your car!)
* New window channel (if necessary, check its condition)
* Automotive urethane adhesive (specifically designed for auto glass)
* Primer (if needed, check the adhesive instructions)
* Masking tape
* Safety glasses
* Work gloves
* Consult a Repair Manual: A Haynes or Chilton manual for your specific year and model will provide detailed diagrams and instructions. This is crucial for understanding the specific steps and intricacies of your Monte Carlo's door panel and window regulator mechanism.
2. Removing the Door Glass:
* Remove the Interior Door Panel: Carefully pry off the interior door panel using panel removal tools. Be gentle to avoid breaking clips. Your repair manual will show the location of clips and screws.
* Disconnect the Window Regulator: Disconnect the window regulator from the glass. This involves detaching the cables or linkages. Again, your repair manual will be essential here.
* Remove the Weatherstripping: Carefully remove the old weatherstripping surrounding the glass.
* Cut the Old Sealant: Use a utility knife or razor blade to carefully cut the old sealant holding the glass in place. Be extremely cautious to not scratch the door.
* Remove the Glass: Using suction cups, carefully lift the glass out of the door. Have a helper assist to prevent breakage.
3. Installing the New Glass:
* Clean the Door Channel: Thoroughly clean the door channel where the glass will sit, removing all traces of old sealant and debris.
* Prepare the New Glass: Inspect the new glass for any damage. Apply the primer (if required by the adhesive instructions) to the prepared door channel.
* Apply New Sealant: Apply a bead of automotive urethane adhesive evenly along the door channel. This is crucial for a watertight seal. Follow the manufacturer's instructions for the adhesive precisely.
* Install the New Glass: Carefully place the new glass into the door channel, ensuring it's properly seated. Use suction cups to hold it in place while the adhesive cures.
* Reinstall the Weatherstripping: Carefully reattach the weatherstripping.
* Reconnect the Window Regulator: Reconnect the window regulator to the new glass.
* Reinstall the Interior Door Panel: Carefully reinstall the interior door panel, ensuring all clips and screws are properly secured.
4. Curing Time:
* Allow the Adhesive to Cure: Allow the urethane adhesive to cure completely according to the manufacturer's instructions. This typically takes several hours or even overnight. Do not operate the window during this time.
Important Considerations:
* Glass Handling: Automotive glass is fragile. Handle it with extreme care to avoid breakage.
* Sealant: Use a high-quality urethane sealant designed for automotive glass. The wrong sealant will lead to leaks.
* Repair Manual: This cannot be stressed enough. A repair manual specific to your 1985 Monte Carlo is essential for success.
This is a general overview. Attempting this repair without experience can be challenging. If you're not comfortable performing this task, it's best to consult a professional auto glass repair shop. They have the experience and tools to do it correctly and safely.
