Document ID# 868617
1998 Saturn SL2/SC2/SW2
 

Rear Window Replacement Coupe

Removal Procedure

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

    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.

    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. Object Number: 866935  Size: SH
    Click here for detailed picture of above image.
  6. Remove the electrical connectors from the bus bars.
  7. Remove the rear compartment lid weatherstrip at the rear window lower panel.
  8. Remove the roof front drip molding. Refer to Roof Drip Molding - Replacement Left Front and Roof Drip Molding - Replacement Right Front in Roof.
  9. Remove the tail lamps and disconnect the wire connectors.
  10. Remove the quarter panel fasteners at the lock pillar, tail lamp opening, and the upper gutter area. Use lightweight wood or foam blocks to hold the quarter panel out.
  11. If the backglass is to be reused, protect the lower molding by folding it over on itself and securing it with masking tape.
  12. If re-using the backglass, apply two 152 mm (6 in) pieces of duct tape to the top and bottom of the glass to prevent it from falling out when the urethane adhesive is cut.

  13. Object Number: 863095  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.

    Notice

    Using thick tape, tape quarter glass encapsulation to protect from damage.

  14. Using a power glass removal tool, cut the urethane seal along the roof from inside, and the urethane seal along the sides and bottom, from outside of the vehicle.
  15. Using piano wire, cut the urethane seal along the bottom corners and side of the windshield in areas as shown in the illustration.
  16. Important

    Rear compartment lid must be in the full open position.

  17. With the aid of a helper, remove the window assembly.
Installation Procedure

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

    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.

  1. 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.
  2. Tape the rear compartment lid in a half open position to provide clearance for installing the glass.

    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.

  3. Clean the entire window opening with a clean, lint-free, alcohol dampened cloth. Allow to air dry.

  4. Object Number: 866574  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.

  5. Preparation for window installation:
  6. Prime the window opening area.
  7. 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:
  8. Bead Dimension
    Object Number: 866533  Size: SH
    Click here for detailed picture of above image.
  9. 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.
  10. Slide the adjuster on the anti-slide clips upward to position the glass up/down.
  11. 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.

    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 the 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 at fresh adhesive material. Water applied on top of the urethane adhesive, during watertest or as a separate operation, will speed up the cure of the urethane.
  14. Inspect for leaks from inside the vehicle. Paddle in extra adhesive at leak points using a tongue depressor or similar flat flexible tool.
  15. Install the rear compartment lid weatherstrip.

  16. Object Number: 866935  Size: SH
    Click here for detailed picture of above image.
  17. Remove the blocks that hold the quarter panels outboard and install the fasteners.
  18. Install the tail lamps.
  19. Install the roof front drip molding. Refer to Roof Drip Molding - Replacement Left Front and Roof Drip Molding - Replacement Right Front in Roof.
  20. Remove the blocks used to hold headliner down.
  21. Connect the electrical connectors to the bus bars.
  22. Install the center high-mount stop lamp.
  23. Install the center high-mount stop lamp cover.
  24. Install the rear window trim finish panel. Refer to Finish Panel Replacement - Upper Rear Trim in Interior Trim.

  Document ID# 868617
1998 Saturn SL2/SC2/SW2