Glass/window/mirrors: Removal & Installation Saab 9-2X I

REMOVAL

Remove the front door trim.

Remove the sealing cover.

Remove the outer mirror assembly.

Remove the mirror gusset.

Scheme 22

Remove the stabilizer (Inner) and stabilizer (Outer).

Scheme 23

Remove the screw at the rear end of weather strip, and remove weather strip.

Scheme 24

Operate the power window switch to move the glass to position shown in the figure, and then remove the two nuts from service holes.

Scheme 25

Take out the door glass.

Scheme 26

INSTALLATION

Install in the reverse order of removal.

Adjust the front door glass.

Tightening torque

Refer to COMPONENT in General Description.

Remove the door glass.

Loosen the nuts to remove the rear sash.

Scheme 27

Disconnect the motor connector.

Loosen the four bolts and two nuts to remove the regulator assembly.

Scheme 28

Loosen the screw to remove motor assembly.

Scheme 29

Install in the reverse order of removal.

Adjust the front door glass.

Tightening torque

Refer to COMPONENT in General Description.

Remove the door trim.

Remove the mirror gusset cover.

Scheme 30

1. Hook

Disconnect the mirror connector.

Remove the screws to remove the mirror assembly.

Scheme 31

Install in the reverse order of removal.

REPLACEMENT

Remove the outer mirror assembly.

Warm the area around the mirror holder (A) with a hair drier until the edges of the mirror holder become soft (about 2 or 3 minutes with a 1,000 W drier).

Use a flat tip screwdriver without sharp edges to lift the mirror out of the mirror holder (A).

Scheme 32

Disconnect the mirror heater connector. (Model with mirror heater)

Warm the area around the mirror holder with a hair drier until the edges of the mirror holder become soft (about 2 or 3 minutes with a 1,000 W drier).

Connect the mirror heater connector. (Model with mirror heater)

Remove the backing of the new double-stick tape, and push the mirror in to install it.

Note. Unless the mirror holder is warmed sufficiently, the mirror holder edges may be damaged or the mirror cracked.

Refer to POWER WINDOW CONTROL SWITCH for removal procedure, because the remote control mirror switch is integrated with power window control switch.

Refer to POWER WINDOW CONTROL SWITCH for installation procedure, because the remote control mirror switch is integrated with power window control switch.

Remove the rear door trim.

Remove the sealing cover.

Remove the stabilizer.

Scheme 33

Remove the front end and rear end of weather strip.

Scheme 34

Remove the two screws to remove the weather strip outer.

Scheme 35

Operate the power window switch to move the glass to position shown in the figure, and then remove two nuts from service holes.

Scheme 36

Remove the two rear sash installation nuts, and then move the rear sash backward.

Remove the glass.

Install in the reverse order of removal.

Note. Make sure the slider (front) and roller (rear) of glass is placed securely in front and rear sash.

Adjust the rear door glass.

Tightening torque

Refer to COMPONENT in General Description.

Remove the rear door glass.

Remove the front sash.

Disconnect the motor connector.

Remove the four bolts and two nuts to remove regulator assembly.

Scheme 37

Remove the screws to remove motor assembly.

Scheme 38

Install in the reverse order of removal.

Adjust the rear door glass.

Tightening torque

Refer to COMPONENT in General Description.

Clean the external circumference of windshield glass with alcohol or white gasoline.

Remove the adhesive layer on the body using cutter knife to obtain smooth face 2 mm (0.08 in) thick.

Scheme 39

1. Adhesive
2. 2 mm (0.08 in)
3. Dam rubber
4. Glass

Clean the body with alcohol or white gasoline to remove thoroughly chips, dusts, and dirt from body face.

Place the glass on body aligning the locating pin of glass side with the hole of body side.

Adjust the glass position to make uniform clearance between body and glass in four corners.

Scheme 40

1. Locating pin
2. Dam rubber
3. Fastener
4. 15 mm (0.591 in)
5. 11 mm (0.433 in)

Remove the glass temporarily from body.

Install the dam rubber.

Fit the mark (B) on molding to the notch (A) of glass side, and install the molding to the whole glass edge.

Scheme 41

Apply two kinds of primer to the adhesive layer of glass using sponge.

Glass primer

ESSEX U-401 (for undercoat) and ESSEX U-402 (for overcoat) or equivalent

Apply primer to adhesive layer of body.

Painted surface primer

ESSEX U-413 or equivalent

Note. Primer once attached to painted surface of the body and internal trim is hard to wipe off. Mask the circumference of such areas. Let the primer dry for about ten minutes before installing the glass. Do not touch the surface coated with primer.

Scheme 42

1. Application of primer
2. Glass side
3. Body side

Cut off the cartridge nozzle tip as shown and set it in sealant gun.

Scheme 43

1. 10 mm (0.39 in)
2. 15 mm (0.59 in)

Apply adhesive to the glass end surface as shown.

Adhesive

ESSEX U-400HV or equivalent

Scheme 44

1. 12 - 15 mm (0.47 - 0.59 in)

Fit the locating pins using suction rubber cup to install the windshield glass.

Scheme 45

Lightly press the windshield glass for tight fit.

Make flush the adhesive surface jutted out using spatula.

After completion of all work, allow the vehicle to stand for about 24 hours.

Note. When the door is opened/closed after glass is bonded, always lower the door glass and then open/close it carefully. Move the vehicle slowly. For minimum drying time and time the vehicle must be left standing before driving after bonding, follow the instructions or instruction manual from adhesive manufacturer.

After curing of adhesive, pour water on external surface of vehicle to check that there are no water leaks.

Note. When a vehicle is returned to the user, tell him or her that the vehicle should not be subjected to heavy impact for at least three days.

Install the cowl panel.

Remove the rear wiper motor.

Disconnect the electrical connector from rear defogger terminal.

Remove the glass in the same procedure as for windshield glass.

Apply adhesive in the same procedure as for windshield glass.

Insert the glass locating pin into the rear gate hole, and after pushing on the area around the locating pin to secure it, push lightly all around the area to seal it.

About one hour after installation, conduct a water leak test.

Scheme 46

1. Upper side
2. Molding
3. Glass
4. Adhesive
5. Lower side
6. Glass
7. Molding
8. Adhesive

After completion of all work, allow the vehicle to stand for about 24 hours.

Note. When the door is opened/closed after glass is bonded, always lower the door glass and then open/close it carefully. Move the vehicle slowly. For minimum drying time and time the vehicle must be left standing before driving after bonding, follow the instructions or instruction manual from adhesive manufacturer. When a vehicle is returned to the user, tell him or her that the vehicle should not be subjected to heavy impact for at least three days.

Connect the rear defogger terminals.

Install the rear wiper.

Remove the glass in the same procedure as for windshield glass.

Scheme 47

1. Rear quarter glass
2. Molding
3. Adhesive
4. Dam rubber
5. Locating pin
6. Rear gate glass

Cut off the nozzle tip as shown in the figure.

Scheme 48

1. Locating pin
2. Dam rubber
3. Adhesive
4. Molding
5. 12 - 15 mm (0.47 - 0.59 in)
6. 15 mm (0.59 in)
7. 10 mm (0.39 in)

Install the glass in the same procedure as for windshield glass.

After completion of all work, allow the vehicle to stand for about 24 hours.

Note. When the door is opened/closed after glass is bonded, always lower the door glass and then open/close it carefully. Move the vehicle slowly. For minimum drying time and time the vehicle must be left standing before driving after bonding, follow the instructions or instruction manual from adhesive manufacturer.

After curing of adhesive, pour water on external surface of vehicle to check that there are no water leaks.

Note. When a vehicle is returned to user, tell him or her that the vehicle should not be subjected to heavy impact for at least three days.

Note. The spring cannot be reused. Prepare a new spring before removal.

Turn the mirror base 90° clockwise or counterclockwise to remove it.

Scheme 49

Remove the spring from mirror base.

Scheme 50

If the mirror base is damaged, remove the mirror base using piano wire or spatula, etc.

If removing the mirror base, remove the remaining adhesive thoroughly, and then fit the mirror base to mark on windshield glass to install.

Adhesive

REPAIR KIT IN MR (Part No. 32005173) or equivalent

Verify that the mirror base is adhered securely, and then install the spring.

Install in the reverse order of removal.

Remove the driver side lower cover, and then remove the wiper deicer switch.

Scheme 51

Install in the reverse order of removal.