Document ID# 868388
1998 Saturn SL2/SC2/SW2
 

Windshield Replacement Coupe

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.

  1. Remove the roof front drip molding. Refer to Roof Drip Molding - Replacement Left Front and Roof Drip Molding - Replacement Right Front in Roof.
  2. Remove the air inlet grille panel and disconnect the windshield washer hose.
  3. Remove the rearview mirror.
  4. Remove the instrument panel-upper trim panel. Refer to Trim Plate Replacement - Instrument Panel (I/P) Upper in Instrument Panel, Gages, and Console.

  5. Object Number: 865456  Size: SH
    Click here for detailed picture of above image.

    Caution

    If broken glass falls into defroster outlets, it can be blown into the passenger compartment and cause injuries. To help avoid personal injury, cover the defroster outlets before replacing windows.

    Important

    Make certain the seal on the forward edge of the instrument panel-upper trim panel is not trapped between the windshield and spaceframe. If so, remove the seal and place on forward edge of the instrument panel-upper trim panel.

  6. Remove the windshield garnish moldings.
  7. Remove the sunshades and sunshade supports.
  8. Remove the roof front compartment bezel, if equipped.
  9. Remove the right front assist strap fastener cover by prying gently between the headliner and the cover on the outboard side. Once the cover unsnaps from the clip, push the cover inward. Remove the fasteners and remove the assist strap.
  10. Lower the front half of the headliner. Use lightweight wood or foam block to hold the headliner down.
  11. 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.


    Object Number: 863090  Size: SH
    Click here for detailed picture of above image.

    Notice

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

  12. Using a power glass removal tool, cut the urethane seal along the roof from inside the vehicle and the bottom and sides from outside the vehicle. Open the hood to gain access to the bottom.
  13. Using piano wire, cut the urethane seal along the bottom corners and side of the windshield in areas as shown in the illustration.
  14. With the aid of a helper, remove the glass.
  15. 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 windshield, if being reused.
Installation Procedure

    Object Number: 866515  Size: MF
    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. Clean the entire window opening and glass bonding surfaces with a clean, lint free, alcohol dampened cloth. Allow to air dry.
  2. 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. 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 the area (A) area.

      Important

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

    3. With a new dauber apply 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 urethane.
  5. 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:
  6. Bead Dimension
    Object Number: 866533  Size: SH
    Click here for detailed picture of above image.
  7. 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.
  8. 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.

  9. 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.
  10. 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.

  11. 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 urethane adhesive, during watertest or as a separate operation, will speed up the cure of the urethane.
  12. Inspect for leaks from inside the vehicle. Paddle in extra adhesive at leak points using a tongue depressor or similar flat flexible tool.
  13. Remove the blocks used to hold the headliner down.
  14. Install the windshield garnish molding.
  15. Install the roof front compartment bezel, if equipped.
  16. Install the right front assist strap.
  17. Install the sunshades and the sunshade supports.
  18. Install the instrument panel - upper trim panel. Refer to Trim Plate Replacement - Instrument Panel (I/P) Upper in Instrument Panel, Gages, and Console.

  19. Object Number: 866539  Size: SH
    Click here for detailed picture of above image.
  20. Install the rearview mirror.
  21. Connect the windshield washer hose, and install the air inlet grille panel.
  22. Install the roof front drip molding. Refer to Roof Drip Molding - Replacement Left Front and Roof Drip Molding - Replacement Right Front in Roof.

  Document ID# 868388
1998 Saturn SL2/SC2/SW2