Vauxhall Workshop Service and Repair Manuals

Rear Window, Remove and Install or Replace - F69 with BO-46974

Note:   This document describes the removal of the rear window using the Glass Removal System BO-46974 . Individual steps in the operation for non-destructive removal of the rear window are described as an addition to the existing video VT 54.

Warning:   To avoid injuries to the hand and eye area, always put on gloves and goggles from the Tool Kit BO-46974 before starting work.

The Tool BO-46974 is recommended for non-destructive removal of the glass. You will find further information in the video VT 54.

Note:   Park vehicle on a flat surface and move front wheels to the straight ahead position.

  Remove

3.   Detach interior light •   Unclip interior light •   Disconnect 6x wiring harness plug

4.   Detach roof frame inner panelling •   Detach roof frame inner panelling from C-pillar inner panelling •   Unclip 3x clip for roof frame inner panelling (arrows) Note:   If present: Release and disconnect auxiliary brake lamp wiring harness plug (1).

5.   Detach rear handles, right and left •   Prise off panels – Unscrew and remove 4x fastening screws 6.   Detach inner panelling, C-pillars •   Unclip 4x screw covers •   Unscrew 4x bolt •   Unclip 5x clip – Remove inner panelling, C-pillars

8.   Pull away upper window trim strip (1)

9.   Measure rear window Note:   Measure the diagonal length of the rear window and cut off the cutting wire at four times the length, approx. 5240 mm . The circumference of the roll of wire is approx. 1 metre.

11.   Push awl through bed of adhesive •   Push awl through the bed of adhesive in the upper left area of the C-pillar Note:   Ensure that the rear window is not damaged as otherwise stress cracks may occur in the rear window. Mask off the area of the body with fibre tape where the penetration is to be made. 12.   Insert the cutting wire •   Thread cutting wire into the bore in the awl and bend over •   Draw cutting wire into the interior of the vehicle as far as the centre of the rear window with the pointed awl

17.   Position the winch with two reels in the vehicle •   Position winch (1) in the left area of the rear window •   Attach cutting wire (2) to winch Note:   Ensure the cutting wire is laid correctly around the pulley of the winch – Insert ratchet and apply tension to the cutting wire 18.   Cut out rear window •   Cut out rear window until the cutting wire reaches the height of the reel – Arrow shows the direction in which the cutting wire is running

19.   Position the winch with two reels in the vehicle •   Position winch (1) in the lower left area of the rear window Note:   Ensure the cutting wire (2) is laid correctly around the pulley of the winch. – Insert ratchet and apply tension to the cutting wire 20.   Cut out rear window Note:   It is necessary to apply additional tensioning force when cutting in the area of the window radius. Use lubricant on the pulley. •   Cut out rear window until the cutting wire reaches the height of the reel Note:   Protect parcel shelf from damage. – Arrow shows the direction in which the cutting wire is running

21.   Position both winches in the vehicle •   Position winch with two reels (1) in the lower right hand area of the rear window •   Position winch with one reel (3) in the upper left area of the rear window Note:   Ensure the cutting wire (2) is laid correctly around the pulley of the winch. – Attach cutting wire to winch – Insert ratchet and apply tension to the cutting wire 22.   Cut out rear window •   Cut out rear window until the cutting wire reaches the height of the reel Note:   Protect parcel shelf from damage. – Arrow shows the direction in which the cutting wire is running

23.   Position the winch with two reels in the vehicle •   Position winch (1) in the right hand area of the rear window Note:   Ensure the cutting wire (2) is laid correctly around the pulley of the winch. Note:   Winch with one reel (3) remains in position. – Insert ratchet and apply tension to the cutting wire 24.   Cut out rear window Note:   It is necessary to apply additional tensioning force when cutting in the area of the window radius. Use lubricant on the pulley. •   Cut out rear window until the cutting wire reaches the height of the reel Note:   Protect parcel shelf from damage. – Arrow shows the direction in which the cutting wire is running

25.   Position the winch with two reels in the vehicle •   Position winch (1) in the upper right hand area of the rear window Note:   Ensure the cutting wire (2) is laid correctly around the pulley of the winch. Note:   Winch with one reel (3) remains in position. – Insert ratchet and apply tension to the cutting wire 26.   Cut out rear window Note:   It is necessary to apply additional tensioning force when cutting in the area of the window radius. Use lubricant on the pulley •   Cut out rear window with both winches one after the other until the cutting wire reaches the height of the reel Note:   Protect moulded headlining from damage – Arrow shows the direction in which the cutting wire is running

27.   Position winch with one reel in the vehicle •   Position winch (3) in the upper centre area of the rear window Note:   Ensure the cutting wire (2) is laid correctly around the pulley of the winch. Note:   Winch with two reels (1) retains its position. – Insert ratchet and apply tension to the cutting wire 28.   Cut out rear window •   Cut out windscreen until the cutting wire reaches the height of the reel Note:   Protect moulded headlining from damage – Arrow shows the direction in which the cutting wire is running

29.   Position the winch with two reels in the vehicle •   Position winch (1) in the upper left area of the rear window Note:   Ensure the cutting wire (2) is laid correctly around the pulley of the winch. Note:   Winch with one reel (3) remains in position. – Insert ratchet and apply tension to the cutting wire 30.   Cut out rear window •   Cut out rear window until the cutting wire has cut through the adhesive bed completely Note:   Protect moulded headlining from damage. – Arrow shows the direction in which the cutting wire is running •   Remove cutting tool completely

32.   Cut down the bead of adhesive on the vehicle •   Using the tool supplied, remove the adhesive bead down to a thickness of approx. 1 mm

  Install

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