Vauxhall Workshop Service and Repair Manuals

Tailgate Window, Remove and Install or Replace F08 (BO-46974)

  Remove

3.   Detach wiper arm (1) KM-6626-20 •   Detach cap •   Unscrew nut 4.   Detach centre brake light (4) •   Remove 3x clips •   Disconnect wiring harness plug. 5.   Remove tailgate inner panelling (2) •   Unscrew 4x bolt •   Remove 7x clips 6.   Detach inner seal of tailgate window •   Pull away tailgate window weatherstrip (3)

8.   Remove rear window wiper motor •   Unscrew 3x bolts (arrows) •   Disconnect wiring harness plug. •   Remove clip

10.   Measure the diagonal of the windscreen, cut wire to length •   Cut off cutting wire to four times the required length, approx. 4720 mm

11.   Insert wire with pliers •   Using pliers (2), insert the cutting wire (1) through the adhesive bed in the left centre area of the rear window and pull in a length of approx. 500 mm

12.   Lay the cutting wire all the way round •   Lay it under the window frame using fabric tape and the guide needles (1) found in the accessories for BO-46974

13.   Insert the second end of the wire •   Cutting wire must overlap when pulled through the adhesive bed

15.   Position the cutter •   Position the winch with the 2 winding heads on the lower left-hand side of the tailgate window •   Attach cutting wire (1) to winch •   Insert transfer ratchet and pre-tension cutting wire Note:   Check that the cutting wire is laid correctly at the winch deflection roller 16.   Cut out the tailgate window Note:   Use a lubricant on the deflection roller, more pulling force is required to cut in the area of the tailgate window corners •   Cut out the tailgate window using the winch and the two winding heads until the cutting wire is level with the winding head •   Arrow shows the path taken by the cutting wire

17.   Position the cutter •   Position the winch with the 2 winding heads on the lower right-hand side of the tailgate window •   Insert transfer ratchet and pre-tension cutting wire (1) Note:   Check that the cutting wire is laid correctly at the winch deflection roller 18.   Cut out the tailgate window •   Cut out the tailgate window using the winch and the two winding heads until the cutting wire is level with the winding head •   Arrow shows the path taken by the cutting wire

19.   Position the cutter •   Position the winch with the 2 winding heads on the right-hand side of the tailgate window •   Insert transfer ratchet and pre-tension cutting wire (1) Note:   Check that the cutting wire is laid correctly at the winch deflection roller 20.   Cut out the tailgate window Note:   Use a lubricant on the deflection roller, more pulling force is required to cut in the area of the tailgate window corners •   Cut out the rear quarter window using the winch and the two winding heads until the cutting wire is level with the winding head •   Arrow shows the path taken by the cutting wire

21.   Position the cutter •   Position the winch with the 2 winding heads on the upper right-hand side of the tailgate window •   Insert transfer ratchet and pre-tension cutting wire (1) Note:   Check that the cutting wire is laid correctly at the winch deflection roller 22.   Cut out the tailgate window Note:   Use a lubricant on the deflection roller, more pulling force is required to cut in the area of the tailgate window corners •   Cut out the tailgate window using the winch and the two winding heads until the cutting wire is level with the winding head •   Arrow shows the path taken by the cutting wire

23.   Position the cutter •   Position the winch with the 2 winding heads on the upper left-hand side of the tailgate window •   Insert transfer ratchet and pre-tension cutting wire (1) Note:   Check that the cutting wire is laid correctly at the winch deflection roller 24.   Cut out the tailgate window •   Cut out the tailgate window using the winch and the two winding heads until the cutting wire is level with the winding head •   Arrow shows the path taken by the cutting wire

25.   Position the cutter •   Position the winch with the 2 winding heads on the left-hand side of the tailgate window •   Insert the second end of the wire into the second winding head and tension 26.   Cut out the tailgate window Note:   Use a lubricant on the deflection roller, more pulling force is required to cut in the area of the tailgate window corners •   Continue cutting until the cutting wire has cut through all the adhesive bead – Arrow shows the path taken by the cutting wire •   Remove cutting tools

30.   Cut adhesive bead off the tailgate window •   Using the tool supplied (1), remove the adhesive bead down to a thickness of approx. 1 mm 31.   Cut adhesive bead off the tailgate •   Using the tool supplied (1), remove the adhesive bead down to a thickness of approx. 1 mm

  Install

34.   Apply adhesive bead •   Cut into the tip of the cartridge in such a way that a bead of adhesive approx. 13 mm thick is produced

37.   Attach inner seal of tailgate window (1) •   Insert weatherstrip around the edge of tailgate window (2) Note:   Start at the area marked by the arrow when fitting the seal to the tailgate welding flange