Document ID# 868491
1998 Saturn SL2/SC2/SW2
 

Rear Window Replacement Sedan

Removal Procedure

    Caution

    Always wear heavy gloves and safety glasses when handling glass to minimize the risk of injury.

    Notice

    Place protective covers on body to prevent paint damage.


    Object Number: 865251  Size: SH
    Click here for detailed picture of above image.

    Important

    Both body lock pillar upper moldings must be removed.

  1. Remove the rear window trim finish panel. Refer to Finish Panel Replacement - Upper Rear Trim in Interior Trim.
  2. Remove the center high-mount stop lamp cover.
  3. Remove the fasteners from the center high-mount stop lamp and disconnect the wire connector.
  4. Lower the rear half of the headliner. Use lightweight wood or foam blocks to hold the headliner down.
  5. Remove the electrical connectors from the bus bars, rear window defogger. Locate the electrical connectors so as not to damage the wiring/connectors when using the urethane power removal tool.
  6. Remove the roof side outer rear panel. Refer to Roof Side Outer Rear Panel Replacement in Roof.

  7. Object Number: 865756  Size: SH
    Click here for detailed picture of above image.
  8. Remove the quarter panel fasteners at the lock pillar and the upper gutter area. Use lightweight wood or foam blocks to hold the quarter panel out.

  9. Object Number: 865488  Size: SH
    Click here for detailed picture of above image.

    Caution

    When using power tools that may create smoke when cutting urethane sealant, work should be done in a well ventilated area and/or with a NIOSH/MSHA Approved air supplied respirator to prevent possible harmful exposure.

    When the urethane adhesive is heated enough to give off smoke, high levels of methylene diisocyanate (MDI) may be present.

    Unprotected exposure to methylene diisocyanate (MDI) may result in severe, chronic, debilitating respiratory problems.

    Notice

    Care must be taken not to damage the roof when using power glass removal tool.

  10. With the power glass removal tool, cut the urethane seal along the roof, down the sides and along the rear window lower panel between the rear compartment lid hinges from inside of the vehicle.
  11. Use piano wire to cut the urethane at the lower corners. Feed the wire under the glass at the C-pillar through the inside and back out at the rear window lower panel, then around the outside of bead. Use a sawing motion to cut the urethane.
  12. With the aid of a helper, remove the window assembly.
  13. Remove the old urethane with a razor knife leaving a thin film, approximately 1-2 mm (0.04-0.08 in) around the perimeter of the window opening and the window assembly, if being reused.
Installation Procedure

    Object Number: 865668  Size: SH
    Click here for detailed picture of above image.

    Notice

    Loose material and/or a rough surface on remaining urethane may cause sealing problems during installation.

    Important

    The glass anti-slide clips will be damaged in the removal process. Make certain the anti-slide clips are replaced with new service parts. Do not slide the adjuster upward until the window assembly is installed.

  1. Clean the entire window opening and glass bonding surfaces with a clean lint-free, alcohol dampened cloth. Allow to air dry.
  2. Important

    If applied molding becomes loose from the edge of the glass, clear and black prime the affected area. Allow to air dry. Apply a thin bead of urethane and install the molding.


    Object Number: 868268  Size: MF
    Click here for detailed picture of above image.

    Notice

    To prevent corrosion, paint damage around the window opening by the power glass removal tool must be covered with pinchweld primer. Do not prime over existing urethane. Follow manufacturers recommendations for drying time.

    Notice

    To avoid damage to the outer edge of the glass, be careful not to scratch the glass when removing urethane with a razor blade.

    Notice

    Loose urethane and/or rough surfaces may cause sealing problems during installation. For cars with a sunroof, it is important to install the fasteners to the new roof assembly before the roof is installed in place.

  3. Preparation for window installation:
  4. Tape the rear compartment lid in a half open position to provide clearance for installing the glass.
  5. Prime the window opening area.
    1. Shake the glass primer, Black #2 or equivalent, well before applying.
    2. Important

      The primer area has a minimum width diameter of 18 mm (0.71 in) in area (A) area.

      Important

      Use the line along the top of the rear window assembly below the rear window assembly upper molding as a guide when applying primer.

    3. With a new dauber apply the glass prep primer , Black #2 or equivalent, around the entire perimeter over Clear #1, or equivalent.
    4. Allow the primer to dry 5 minutes before applying the urethane.
  6. Apply a smooth and continuous bead of adhesive directly to the old urethane adhesive in the glass opening or to the glass. Apply according to the following dimensions:
  7. Bead Dimension
  8. With the aid of a helper, lift the glass into the window opening. Use the notches in the roof panel to center the glass to the vehicle. Make certain the lip of the applied molding laps over the roof feature line.

  9. Object Number: 865490  Size: SH
    Click here for detailed picture of above image.

    Notice

    Until the new urethane has cured, air pressure from a closing door may cause the glass to move. To prevent this, lower the opposite side door window a minimum of 76 mm (3 in) before closing the door.

  10. Slide the adjuster on the anti-slide clips upward to position the glass up/down.
  11. Important

    The vehicle must remain at normal room temperature for 6 hours to complete proper cure of the adhesive. Refer to the manufacturer's recommendation.

  12. Press the glass firmly to wet-out and set adhesive. Use care to avoid excessive squeeze out which would cause an appearance problem. Using duct tape or equivalent, tape glass up to the roof.
  13. Watertest the vehicle at once using a soft spray. Use warm or hot water if available. Do not direct a hard stream of water on fresh adhesive material. Water applied on top of urethane adhesive, either during watertest or part of a separate operation, will speed up the cure of urethane.
  14. Notice

    Refer to Fastener Notice in Cautions and Notices.

  15. Inspect for leaks from inside the vehicle. Paddle in extra adhesive at leak points using a tongue depressor or similar flat flexible tool.
  16. Install the quarter panel fasteners.
  17. Tighten

    Tighten the fasteners to 9 N·m (80 lb in).


    Object Number: 865246  Size: SH
    Click here for detailed picture of above image.
  18. Install the roof side outer rear panel. Refer to Roof Side Outer Rear Panel Replacement in Roof.
  19. Connect the electrical connectors to bus bar.
  20. Install the headliner.
  21. Install the center high-mount stop lamp.
  22. Install the center high-mount stop lamp cover.
  23. Install the rear window trim finish panel. Refer to Finish Panel Replacement - Upper Rear Trim in Interior Trim.

  Document ID# 868491
1998 Saturn SL2/SC2/SW2