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Home >> Chevrolet >> 2004 >> Malibu Base >> Repair and Diagnosis >> Body & Frame >> Windows >> Stationary Window System >> Repair Instructions >> Roof Window Replacement >> Removal Procedure

Removal Procedure

    CAUTION: Refer to Cracked Window Caution in Cautions and Notices.
  1. Before cutting out a stationary window, apply a double layer of masking tape around the perimeter of the painted surfaces and the interior trim.
  2. CAUTION: Refer to Defroster Outlet Caution in Cautions and Notices.
  3. Cover the following parts to protect from broken glass:
    • Upper dash pad
    • Defroster outlets and A/C outlets
    • Seats and carpeting
  4. Fig 1: View Roof Window Reveal Molding
    GM1326381Courtesy of GENERAL MOTORS CORP.
    CAUTION: Refer to Glass and Sheet Metal Handling Caution in Cautions and Notices.
    IMPORTANT: The roof window reveal molding (3) is a one piece molding and fills the cavities between the body and the roof window (1).
  5. Inspect the roof window reveal molding for damage. If the roof window reveal molding is damaged or becomes detached from the window, the reveal molding can not be reused and must be replaced. Refer to Roof Window Reveal Molding Replacement .
  6. Fig 2: Removing Window From Urethane Adhesive
    GM1326373Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Keep the cutting edge of the tool against the window.
  7. Remove the window from the urethane adhesive.
    • Leave a base of urethane approximately 2 mm (0.078 in) on the pinch-weld flange.
    • The only suitable lubrication is clear water.
    • UseJ 24402-A  . See Special Tools and Equipment . J 39032  or equivalent in order to cut the urethane bead to remove the window. See Special Tools and Equipment .
  8. Fig 3: Removing Window From Vehicle
    GM1326374Courtesy of GENERAL MOTORS CORP.
  9. With the aid of an assistant, remove the window from the vehicle.