LEMON Manuals: Even more car manuals for everyone: 1960-2025
Home >> Saturn >> 2005 >> Ion Red Line >> Repair and Diagnosis >> Body & Frame >> Windows >> Stationary Window System >> Repair Instructions >> Windshield Replacement >> Removal Procedure
April 5, 2026: LEMON Manuals is launched! Read the announcement.

Removal Procedure

    IMPORTANT: Before cutting out a stationary window, apply a double layer of masking tape around the perimeter of the painted surfaces and the interior trim.
  1. Open the hood.
  2. Remove the windshield wiper arms and blades. Refer to Wiper Arm Replacement in Wipers/Washer Systems.
  3. Remove the air inlet grille. Refer to Air Inlet Grille Panel Replacement in Body Front End.
  4. Remove the windshield frame appliques. Refer to Applique Replacement - Windshield Frame .
  5. Remove the rearview mirror. Refer to Rearview Mirror Replacement .
  6. CAUTION: If broken glass falls into the defroster outlets, it can be blown into the passenger compartment and cause personal injury.
  7. Cover the following parts to protect from broken glass:
    • Upper dash pad
    • Defroster outlets and A/C outlets
    • Seats and carpeting
  8. Fig 1: Removing/Installing Windshield
    GM880612Courtesy of GENERAL MOTORS CORP.
    CAUTION: When working with any type of glass or sheet metal with exposed or rough edges, wear approved safety glasses and gloves in order to reduce the chance of personal injury.
  9. Remove the lower windshield supports (1) from the cowl panel, if equipped.
  10. Fig 2: Identifying Lower Windshield Supports
    GM326804Courtesy of GENERAL MOTORS CORP.
  11. Cut the urethane adhesive along the windshield pillars:
    • Leave a base of urethane on the pinchweld flange.
    • The only suitable lubrication is clear water.
    • From the outside of the car, use J 39032  to cut the urethane along the sides of the window. See Special Tools .
  12. From the inside of the car, cut the urethane bead along the top and the bottom of the windshield.
  13. Remove the windshield (1) from the vehicle with the aid of an assistant (2).
  14. Fig 3: Removing/Installing Windshield
    GM441419Courtesy of GENERAL MOTORS CORP.