How do you remove the roof skin on an 03 Saturn ion?

Answer 1

The short answer: The same way you remove a windshield.

My 2007 Saturn Ion Coupe roof was held in place with 6 nuts, and what appears to be the same glue used to hold the windshield and back glass. However your working blind and up and over humps. It took us about 4 to 5 hours, or about 3 times longer than it took to wire cut out the windshield out. We thought we wire cut through all the glue; however, there were still four areas on the inside of the two bolts in front and the two bolts in back that were still attached. After further investigation, I found there were four areas of glue about 1 to 2 inches long we missed because the glue deviates toward the center of the vehicle at these four bolts. While cutting off the roof - it worked best with one person on the inside and one on the outside pulling the wire back and forth; however, for these four trouble spots - pulling the wire back and forth on the outside of the vehicle worked best. A triumphant thump occurred as each of the four remaining spots where cut.

Steps: Remove Drip molding (4 pieces), Cowl grille, Windshield, Back glass, Interior pillar trim, Headliner, Sunroof, & Six 10mm nuts (two in front, two in back, and one on each side).

I used the $24.99 Professional Windshield Removal Kit by Harbor Freight - it has enough wire for both windows and the roof. Plus you will need the tool to push the wire under the roof skin and through the adhesive. FYI: I was able to wiggle and push the tool with wire through the windshield adhesive fairly easy; however, due to working blind and up and over the roof rail, I found it easier to heat up the tool and melt my way through the adhesive.

Good Luck --- Rob