Windshield - Installation On Convertible Vehicles
89Saab06FILE IN: S.I. Man VOL. I
SEC. A-8
PG. 118
ISSUE: 09/89-1176
SUBJECT: CONVERTIBLE WINDSHIELD INSTALLATION
APPLICATION: ALL 900 CONVERTIBLE MODELS
The windshield in the 900 Convertible is glued to the windshield frame, thus providing a measure of stiffness to the car's structure. Proper windshield replacement techniques are critical to maintaining the integrity and safety of the car. The procedure provided in this S.I. should be followed by both dealership technicians and any sublet glass installation specialists.
It will be helpful to review the entire procedure before beginning.
NOTE
The car must remain in one place throughout the windshield removal, installation, water test and drying period. The drying period alone is a minimum of 15 hours (at 70~F). A suitable area that will allow the car to remain unmoved should be chosen.
Parts Required
CV Windshield Kit P/N 82 84 200
Adhesive Kit P/N 30 07 119
Adhesive (300 ml tube) P/N 30 16 045
Spacer Blocks (2) P/N 69 91 244
Sikaflex 255 P/N 30 07 127
Figure 1:
Windshield Removal Procedure
In order to cut out the old windshield, all the interior trim must be removed from around the windshield. Removal of the A-pillar trim requires that the dash panel be unfastened and moved back slightly. Screw head sizes are provided in parenthesis.
1. Put the top down.
2. Remove the windshield wiper arms.
3. Remove the sunvisors and their support brackets (Figure 1).
4. Remove the retaining screws from the lock fitting end caps (Figure 1).
5. Loosen the upper portion of the left and right A-pillar trim by removing the three clips on each side.
Figure 2:
6. Cut through the sealant around the lock fitting end caps and remove them.
7. Remove the two screws (T20) which secure the rear view mirror to the windshield header (Figure 2).
8. Unplug the connector for the rear view mirror light and remove the mirror.
9. Remove the padding from the crossmember above the windshield by pulling down in the center.
10. Remove the two T10 screws in each dashboard speaker grill. Carefully lift up each grill using a screw driver as a lever.
11. Disconnect the speaker leads, the alarm LED lead (LH side) and remove the defroster tubes. The speaker grills can now be removed.
12. Remove the radio head and the basket from the dash.
Figure 3:
13. Remove the two dash panel retaining screws (T25) located inside the speaker grill openings (Figure 3).
Figure 4:
14. Remove the two screws securing the dash under the glove box (T25 or Phillips), see Figure 4.
Figure 5:
15. Remove the long screw (T20 or Phillips) retaining the dash insert on the left side (Figure 5).
16. Remove the two screws (T20 or Phillips) and the clip securing the steering column cover. The clip is a quarter-turn twist lock.
17. Pull back on the dash and push forward on the A-pillar trim to remove them.
NOTE
On 86-87 models, the A-pillar trim may be partially held by the A-pillar seal retainers. If this is the case, just move the trim out of the way so that it will not be damaged by the cutter.
18. Open the hood.
19. Remove the rubber trim strip from the windshield.
20. Protect the painted area around the windshield with fabric tape or duct tape.
Figure 6:
21. Cut the windshield out as follows:
A. Cut across the the top of the windshield and the upper part of both A-pillars using a straight blade from inside the car (Figure 6).
Figure 7:
B. Before using the cutter to release the remaining sections of the windshield, first cut through the retainer strip with a razor knife as shown in Figure 7. This will enable the hooked cutter blade to get up and around to the glue bead without first having to cut through the retainer strip.
Figure 8:
C. Using a hooked cutter blade and working from the outside of the car, cut around the lower part of the A-pillars and the bottom of the windshield (Figure 8).
D. Remove the glass. Remove the protective tape from around the windshield frame.
Preparation and Gluing of New Windshield
1. Using the trimming knife, cut down the bead of adhesive on the windshield flange to a maximum height of 2 mm.
NOTE
Old adhesive which adheres firmly to the windshield frame provides a good anchor for the new bead of adhesive. Any loose adhesive in the frame channel must be removed.
2. Touch up any paint damage caused by the cutter blade.
NOTE
To prevent rusting, it is very important that any nicks in the paint are properly covered with touch-up paint.
3. Mask the inside of the windshield with 2 in. wide masking tape, covering the stripes to protect them from excess glue or primer.
4. Trim any excess laminate material from the edge of the glass.
NOTE
Only the cleaning solution, primer and adhesive supplied in Saab Installation Kit, P/N 30 07 119, are tested and approved for use on Convertible windshields.
5. Carefully wash the edge of the windshield with the cleaning fluid provided in the installation kit. If new body panels have been installed, clean any bare windshield frame pieces which do not have a layer of old glue. Wet a cloth with the cleaning fluid and then wipe the surfaces to be cleaned. Use a clean, lint-free cloth to dry the cleaning fluid. Do not allow the fluid to dry naturally. Avoid touching the windshield glass or body surfaces to be glued once they have been cleaned.
Figure 9:
Figure 9:
Figure 10:
6. Before installing the preformed retainer strip on the glass, make sure that it conforms correctly to the shape of the windshield (Figure 9). If not, insert a length of sheathed hood release cable into the strip to prevent kinking, and then bend the strip to conform to the windshield (See Figure 10).
Figure 11:
7. Test fit the windshield in the frame. Trim or add spacer blocks (P/N 69 91 244) to achieve a 2 mm clearance all the way around the windshield (Figure 11).
8. Remove the windshield from the car and glue the shims in place in the frame.
Figure 12:
9. Install the rubber trim strip into the retaining strip on the glass (Figure 12). Fitting the trim before installing the windshield allows the glass to be adjusted more easily once in place on the car.
Figure 13:
10. Apply primer to the edge of the windshield, and to any areas of the windshield opening that are bare of old glue (Figure 13).
Figure 14:
11. Adjust the shape of the glue nozzle as shown in Figure 14. Warming the nozzle in hot water will make forming the nozzle easier.
Figure 15:
12. Apply a bead of adhesive to the windshield, adjusting the pressure on the applicator gun so that the adhesive will have the shape shown in Figure 15.
Figure 16:
13. Hold the nozzle at right angles to the glass and apply the bead of adhesive along the edge of the strip retainer (Figure 16).
Figure 17:
14. Set the windshield into the frame and check that the rubber trim strip is positioned correctly. Press down on the windshield so that the rubber trim strip is in contact with the frame all the way around (Figure 17).
NOTE
Do not clamp the windshield with any pressure. This would cause too much stress in the corners and crack the glass.
15. Inspect from inside the car to ensure that the glue is spreading inward. Spread the glue out evenly around the frame, removing it from the heavily concentrated areas and adding it to the thinly spread areas.
Figure 18:
Glue Hardening and Leak Testing
NOTE
The glue hardening process is accelerated by moisture and heat. Leak testing can therefore be carried out immediately after windshield installation.
1. Leak test the windshield by pouring water around the outer edge. Then carefully lift the rubber trim strip at the top center and pour water into the channel beneath it (Figure 18).
2. Check for any leaks from inside the car.
3. From the inside of the car, seal any areas that leak by injecting adhesive into the area and spreading it with a putty knife.
4. Wipe any excess adhesive with a clean shop rag and kerosene. Take care not to disturb it before the adhesive has set.
5. Allow car to stand for a minimum of 15 hours for complete adhesive curing.
Reassembly
1. Remove masking tape from the windshield.
2. Reinstall and reconnect all items that were removed or disconnected in steps 2-18 of the Windshield Removal Procedure section. Be sure and perform these steps in reverse order so that the A-pillar trim pieces are installed before the dash is fastened.
NOTE
When fastening the dash, ensure that the control rod for the heater valve is positioned correctly.
3. After installing the lock fitting end caps, apply a bead of Sikaflex 255 in the seam and smooth out the excess. Use kerosene (sparingly) for clean up.
Warranty Information: Labor time allowance for warranty repairs is 3.3 hours (Op # 84310). Sublet installation costs should not exceed the cost of the dealership doing the installation. In any situation, the replacement windshield glass must be purchased from Saab.