Water Leak at the Rear Liftgate Glass. Saturn Saturn 1995

For 1990-2009 cars

# Water Leak at the Rear Liftgate Glass

Subject: | Water Leak at the Rear Liftgate Glass -- Install new Liftgate Glass

Models: | 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.

### Removal Procedure:

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.

1. Remove the liftgate window upper molding retainers. Remove the liftgate upper window molding by pulling at the clip locations to disengage the clips.
2. Remove the liftgate side window molding by pulling at the clip locations.
3. Remove the fasteners from the lower end of the liftgate inner lower panel assembly.
4. Remove the liftgate rubber bumper.
5. Remove the liftgate inner lower panel by pulling at the clip locations to disengage the clips.
6. Remove the fasteners from the center high mount stop lamp housing and discard the wire connector.
7. Remove the electrical connectors from the bus bars and rear window defogger. Position the electrical connectors so as not to damage wiring or connectors when cutting urethane adhesive.
8. Grasp the outer edge of the applique and lift it from the lid.

Carefully remove the inner edge from under the liftgate glass encapsulated molding.

9. Using a small flat blade screwdriver, disengage the wiper arm retaining latch.
10. Remove the wiper arm from the wiper motor shaft.
11. From outside of the vehicle, trim away encapsulation around the perimeter of the liftgate glass using a sharp utility knife.
12. Using a cold knife J24402-A or equivalent, cut the urethane adhesive around the perimeter of the glass. Keep the blade of the knife as close to the edge as possible.
13. 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.
14. From inside the liftgate, use a sharp utility knife to cut the remaining urethane at the glass corners and areas below the wiper motor shaft.
15. Remove the window assembly.

### Installation Procedure

1. Completely remove old urethane from the liftgate.
2. Clean the surface of the liftgate glass opening with isopropyl alcohol and wipe dry.

Notice: Primer and urethane adhesive kit P/N 1234684 is the only recommended product for this procedure.

3. Shake pinchweld primer (Black # 3) well before using. With a new dauber, apply the primer (Black # 3) around the entire perimeter of the liftgate glass opening. Allow it to dry for 10 minutes.
4. Install the applique.
5. Clean the surface of the glass where the adhesive is to be applied with a clean alcohol dampened cloth. Allow it to air dry.
6. Shake the glass prep primer (clear #1) well before using. Apply her glass primer (clear #1) around the entire perimeter of the glass using a dauber. Wipe dry with a clean lint free cloth.

Primer area:

Minimum Area 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 the entire perimeter over the clear #1. Allow it to air dry for 5 minutes.
8. Apply a smooth continuous bead of urethane adhesive around the perimeter of the liftgate glass. Apply urethane up to the edge of the encapsulated molding.

Bead Dimension:

Minimum Width: DIM.B=8 mm (0.32 in)

Minimum Height; DIM.C=13 mm (90.51 in)

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.

9. With the aid of a helper, align the window assembly onto the wiper motor module shaft. Press the glass firmly around the perimeter of the wiper motor shaft and glass to wet out and set the adhesive. Use care to avoid excessive squeeze out which would cause an appearance problem. Use tape from the glass to the liftgate to hold the glass in position until the urethane adhesive is cured
10. Water test the vehicle at once using a soft spray from a hose. 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, either during a water test or as 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 a tongue depressor or similar flat flexible tool.
12. Install the wiper arm to the wiper motor shaft, positioning the wiper arm just below the first rear defroster grid at the bottom of the liftgate glass.
13. Push the retaining latch inward to secure the wiper arm to the wiper motor shaft.
14. Connect the electrical connectors to the bus bar.
15. Install the center high mount stop lamp.
16. Position the liftgate inner lower panel to the vehicle. Push at the attaching clip locations to engage the clip. Install the fasteners.
17. Install the liftgate rubber bumpers.
18. Position the liftgate side window molding to the vehicle. Push at the attaching clip locations to engage the clips.
19. Position the liftgate window upper molding to the vehicle. Push the attaching clip locations to engage the clips.
20. Install the retainers.

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

Part Number | Description | Qty
--- | --- | ---
12346284 | Kit -- Primer and Urethane Adhesive Glass | 2 Required
21097173 | Window Asm -- Liftgate | 1 Required

To receive credit for this repair, submit a claim through the Saturn Dealer System using the appropriate Electronic Labor Time Guide and Labor Operation Code C0710.