Rear Liftgate Glass - Waterleak at Seal
BULLETIN NO.: 95-T-51ISSUE DATE: November, 1995
GROUP/SEQ. NO.: Body-10
CORPORATION NO.: 581503
SUBJECT:
Waterleak at Rear Liftgate Glass (Install New Liftgate Glass)
MODELS AFFECTED:
1996 Saturn Wagons built between VINs TZ161695 and TZ192102
CONDITION:
Some owners of early built Saturn Wagons may experience a leak in the rear liftgate glass seal.
CAUSE:
Skips in the urethane bead that seals the rear liftgate glass to the rear liftgate.
CORRECTION:
Install new rear liftgate glass according to the procedure in this bulletin.
PROCEDURE
Liftgate Window Assembly
CAUTION:
ALWAYS WEAR HEAVY GLOVES AND SAFETY GLASSES WHEN HANDLING GLASS TO MINIMIZE THE RISK OF INJURY.
NOTICE:
Care must be taken to avoid damaging paint around glass during removal.
REMOVAL
1. Remove liftgate window upper molding retainers. Remove liftgate window upper molding by pulling at clip locations to disengage clips.
2. Remove liftgate side window molding by pulling at clip locations.
3. Remove fasteners from lower end of liftgate inner lower panel assembly.
4. Remove liftgate rubber bumper.
5. Remove liftgate inner lower panel by pulling at clip locations to disengage clips.
6. Remove fasteners from center high mount stop lamp housing and disconnect wire connector.
7. Remove electrical connectors from bus bars and rear window defogger. Position electrical connectors so not to damage wiring or connectors when cutting urethane adhesive.
8. Grasp outer edge of applique and lift from liftgate.
9. Carefully remove inner edge from under liftgate glass encapsulated molding.
10. Using a small flat blade screwdriver, disengage wiper arm retaining latch.
11. Remove wiper arm from wiper motor shaft.
12. From outside of vehicle, trim away encapsulation around the perimeter of liftgate glass using a sharp utility knife.
13. Using a cold knife No. J24402-A or equivalent, cut urethane adhesive around the perimeter of glass. Keep blade of knife as close to the edge of glass as possible.
14. Apply two 152 mm (6 in.) pieces of duct tape to the top and bottom of glass to prevent it from falling out when urethane adhesive is cut.
15. From inside the liftgate, use a sharp utility knife to cut the remaining urethane at glass corners and areas below the wiper motor shaft.
16. Remove window assembly.
INSTALLATION
1. Completely remove old urethane from liftgate.
2. Clean the surface of liftgate glass opening with isopropyl alcohol and wipe dry with a clean lint-free cloth.
NOTICE:
Primer and urethane adhesive kit P/N 12346284 is the only recommended product for this procedure.
3. Shake pinchweld primer (Black # 3) well before using. With a new dauber, apply primer (Black # 3) around entire perimeter of the liftgate glass opening. Allow primer to dry 10 minutes.
4. Install applique.
5. Clean surface of glass where adhesive is to be applied with a clean alcohol-dampened cloth. Allow to air dry.
6. Shake glass prep primer (Clear # 1) well before using. Apply glass prep primer (Clear # 1) around the entire perimeter of glass using dauber. Wipe dry with a clean lint-free cloth.
Primer area:
Minimum Width: DIM. A = 18 mm (0.71 in.)
7. Shake glass primer (Black # 2) well before using. With a new dauber, apply glass primer (Black # 2) around entire perimeter over Clear # 1. Allow primer to dry five minutes.
8. Apply a smooth continuous bead of urethane adhesive around perimeter of liftgate glass. Apply urethane up to edge of encapsulated molding.
Bead Dimension:
Minimum Width: DIM. B = 8 mm (0.32 in.)
Minimum Height: DIM. C = 13 mm (0.51 in.)
9. With the aid of a helper, align window assembly onto wiper motor module shaft. Press glass firmly around the perimeter of wiper motor shaft and glass to wet out and set adhesive. Use care to avoid excessive squeeze out which would cause an appearance problem. Use tape from glass to liftgate to hold in position until urethane adhesive is cured.
NOTICE:
Until the new urethane has cured, air pressure from a closing door may cause the liftgate glass to move. To prevent this, lower one window a minimum of 76 mm (3 in.) before closing a door.
10. Watertest vehicle at once using soft spray from a hose. Use warm or hot water if available. Do not direct hard stream of water at 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.
11. Inspect for leaks from inside the vehicle. Paddle in extra adhesive at leak points using tongue depressor or similar flat flexible tool.
12. Install wiper arm to wiper motor shaft, positioning the wiper arm just below the first rear defroster grid at the bottom of the liftgate glass.
13. Push retaining latch inward to secure wiper arm to wiper motor shaft.
14. Connect electrical connectors to bus bar.
15. Install center high mount stop lamp.
16. Position liftgate inner lower panel to vehicle. Push at attaching clip locations to engage clip. Install fasteners.
17. Install liftgate rubber bumpers.
18. Position liftgate side window molding to vehicle. Push at attaching clip locations to engage clips.
19. Position liftgate window upper molding to vehicle. Push attaching clip locations to engage clips.
20. Install retainers.
IMPORTANT:
Vehicle must remain at normal room temperature for six hours to complete proper cure of adhesive. Refer to urethane adhesive manufacturer's recommendations.
PARTS REQUIREMENTS:
12346284 Kit-Primer and Urethane Adhesive Glass -
2 required per vehicle
21097173 Window Asm-Liftgate - 1 required per vehicle
CLAIM INFORMATION:
To receive credit for this repair during the warranty coverage period, submit a claim through the Saturn Dealer System using the appropriate Electronic Labor Time Guide and Labor Operation Code C0710.