Vauxhall Workshop Service and Repair Manuals

Operations - Quick Overview

Areas of Application

Service Literature

Service Instructions,

Technical Information Bulletins

Materials, Products, Tools

Positioning (Cutting Wires)

Wire Lengths/Application/Cutting

Application of Protective Hose

Application of Thermoknife

Application of Oscillating Cutter

PU Activator

Application of Adhesive

Bond Parts

Tensioning Belts

Waiting Periods

Environmental Protection/Disposal

Operations - Details

Areas of Application

All directly adhered glass screens (example: Corsa-B, Tigra)

Windscreen (1)

Rear screen / tailgate screen (2)

Side windows (3)

Does not apply for bolted or rail-mounted screens

Service-Literatur

Service Literature

1   Existing Technical Information Bulletins

2   Brochures (e.g. New Technical Features for new product features)

3   Service Instructions

Vehicle-specific operations and instructions

Materials, Products, Tools

From the "Special Service Tools" catalogue:

Wire Cutter Set MKM-589-B (with protective hose and insert awl)

Thermoknife Set MKM-590-B

Tensioning Belts MKM-591

Window Screen Suction Lifter MKM-641

Oscillating Cutter¹⁾

MKM-846-1E (electric) or

MKM-846-1P (pneumatic)

Knife Set, Tailgate Screen, Tigra²⁾

MKM-846-50

Knife Set, Windscreen, Tigra²⁾ MKM-846-60

Scraper Set²⁾ MKM-846-70

Assembly Tool Set, Tigra MKM-848

¹⁾   Always specify when ordering

E = electric P = pneumatic

²⁾   Suitable for MKM-846-1E and MKM-846-1P

Type

Windscreen

Rear screen

Tailgate screen

Side screens

Kadett-D/ Astra-D

-

-

Wire

-

Ascona-C

-

-

Wire/osc. cutter^*)

-

Kadett-E/ Astra/ Belmont

Wire/thermoknife/ osc. cutter^*)

Wire¹⁾/thermoknife¹⁾/ osc. cutter^*)1)

Wire¹⁾/thermoknife¹⁾/ osc. cutter^*)1)

Wire¹⁾/thermoknife¹⁾/ osc. cutter^*)1)

Astra-F

Wire/thermoknife/ osc. cutter^*)

Wire²⁾/thermoknife²⁾/ osc. cutter^*)2)

Wire/thermoknife/ osc. cutter^*)

-

Corsa-B

thermoknife/ osc. cutter^*)

-

Wire/thermoknife/ osc. cutter^*)

Wire³⁾/thermoknife³⁾

Vectra/ Cavalier

Wire/thermoknife/ osc. cutter^*)

Wire/thermoknife/ osc. cutter^*)

Wire⁴⁾/thermoknife/ osc. cutter^*)

-

Calibra

thermoknife/ osc. cutter^*)

-

Wire⁴⁾/osc. cutter^*)

-

Omega/ Carlton

thermoknife/ osc. cutter^*)

Wire/thermoknife/ osc. cutter^*)

Wire/thermoknife/ osc. cutter^*)

-

Senator-B

thermoknife/ osc. cutter^*)

Wire/thermoknife/ osc. cutter^*)

Wire/thermoknife/ osc. cutter^*)

-

Omega-B

thermoknife/ osc. cutter^*)

Wire/thermoknife/ osc. cutter^*)

thermoknife/ osc. cutter^*)

-

Tigra

osc. cutter^*)

-

osc. cutter^*)

-

Positioning (Cutting Wire)

General

Two technicians are required (to avoid damage)

Wear protective gloves and goggles.

Do not use cutting agents and/or lubricants.

Cutting agents and/or lubricants always lead to a loss of adhesion when the screen is installed.

Remove attaching parts as specified in Service Instructions.

Screens without PU Trim Strips

All screens approved for wire (table, see page 7), except tailgate screen for Vectra/Cavalier and Calibra

Use square wire (MKM - 589 - 1)

Wear protective goggles

Wear safety gloves

Maximum wire length 600 mm/24 in.

Guide cutting wire through adhesive bed from inside outwards Use protective hose to avoid damage

Screens with PU Trim Strips

Vectra/Cavalier and Calibra

Tailgate screen

Construct ad hoc tool for drill bit:

welding rod Ø 3 mm/0.12 in., 90 mm/3.5 in. long, grind to a point

Slide ad hoc tool under trim strip from outside at point shown (A), tilt drill by 90° (parallel to glass surface)

Drill wire application hole from outside inwards (B)

Use protective hose from MKM-589-B.

Pull cutting wire through drilled hole to inside

Wire length 600 mm/24 in.

Wire Lengths/Application/Cutting

General

Position:                 Wire length:

windscreen, rear           600 mm/24 in.

screen and tailgate

screen, side

Windscreen,                  1200 to

rear screen and             1400 mm/

tailgate screen,              48 to 55 in.

upper and lower

Side windows               600 mm/24 in.

Always use protective hose (MKM-589-4)

Screens without PU Trim Strips

All screens approved for wire (see table page 7), except tailgate screen for Calibra and Vectra/Cavalier

Pull cutting wire flat to the edge of the glass on the outside and keep under tension.

Cut on inside.

Avoid damage to the moulded headlining and upholstery in the interior.

Guide handle on inside close to the screen.

Cut to the corner of the screen, then change wire.

Apply corrosion protection if necessary.

Screens with PU Trim Strips

Calibra

Tailgate screen with PU trim strip.

Use protective hose (MKM-589-4)

Cut at side:

Route cutting wire on outside under lip of trim strip (A) and guide along adhesive bead.

Keep cutting wire under tension on outside.

Always cut on the inside (B).

Cut to the corner of the screen, then change wire.

Cutting at top and bottom:

Maximum wire length 1400 mm/ 55 in.

Apply cutting wire and protective hose at corner of screen (A) and apply under lip of trim strip using insert awl (B).

Keep cutting wire under tension on outside.

Cut on inside.

Keep cutting wire horizontal under tension on outside. Cut to corner of screen, then change wire.

Apply corrosion protection if necessary.

Screens with PU Trims Strips (Additional Adhesive Trim Strip Ends)

Vectra/Cavalier

Tailgate screen with PU trim strip.

Cut at sides:

Operation see page 12.

Cut at bottom:

Operation see page 13.

Cut at top:

Heat up trim strip ends with foil adhesive (hot air dryer) and detach from body.

Route cutting wire under ends of trim strip.

Wire application and cutting see page 13.

Apply corrosion protection if necessary.

Adhere trim strip ends with sealing compound, alternatively with glue

Application of Protective Hose

To prevent paint damage and damage to the PU trim strips, use Protective Hose MKM-589-4.

Guide protective hose over cutting wire.

Guide free end of cutting wire through adhesive bed

Route protective hose with insert awl under lip of trim strip.

Cut as described in previous section

Note:

Protective hose will be likewise cut through and must not be reused.

Application of Thermoknife

All screens approved for thermoknife (table page 7).

Ensure adequate ventilation of workplace.

Use prescribed cutting knife (Service Instructions).

Note cutting direction, as specified in operating instructions.

Recut remains of adhesive bead to thickness of approx. 1 mm/0.04 in.

Apply corrosion protection if necessary.

Application of Oscillating Cutter

All screens approved for oscillating cutter (electric or pneumatic) (table page 7).

Note instructions.

Before starting, sharpen knife using commercially available whetting stone at low speed.

Use prescribed knife.

Observe Service Instructions

Example, Tigra tailgate screen (Knife Set MKM-846-50):

Area 1                  Knife MKM-846-4

Area 2                  Knife MKM-846-2

Area 3                  Knife MKM-846-4

Area 4                  Knife MKM-846-3

For recutting, use Scraper Set MKM-846-70.

PU Activator

Only on new screens with PU trim strips.

Sand adhesive surface of PU trim strip with dry sandpaper grain P 80 - P 100.

Blow off adhesive surface with compressed air.

Apply PU activator on adhesive surface.

Allow to dry for 10 minutes.

Apply adhesive to activated surfaces.

Note: For Tigra tailgate screen, do not apply PU activator to black screen print (A).

The PU activator can cause residue to mix with the glass primer (possible disruption of adhesion).

Use only glass primer on screen print.

Important: Note instructions enclosed with adhesive set.

Only PU activator guarantees optimal adhesion of the screen adhesive.

Adhesion

Place screen on holder (1)

Alternatively, use flat commercially available holding frame for working with Betagun (easier application)

Prepare screen.

Apply adhesive using precut triangular nozzle from adhesive set (2).

Apply adhesive only to screen

Bond Parts

Insert screen (3).

Align as specified in Service Instructions.

Apply only light pressure (hand or tensioning belt).

To prevent excessive tension and the risk of glass breakage, maintain a minimum distance of 4 mm/0.16 in. (4).

Tensioning Belts

All screen types have intrinsic pretension. Therefore, tensioning belts must only be applied with light pressure, even for vertical screens.

Important: Risk of glass breakage (tension) after the adhesive has hardened if the screen frame is too close to the body flange.

Minimum distance from glass to body should be 4 mm/0.16 in.

Select correct position of rubber pad:

1 = Correct

2 = Incorrect

Remove tensioning belts after approx. 1 hour, to ensure that the remaining hardening process is free of tension.

Important:   Install tailgate screen for Tigra with Screen Installation Set MKM-848:

MKM-848-1        Upper Spacer

MKM-848-2        Fixing Piece, Side

MKM-848-3        Rear Spacer

Do not use tensioning belts.

Waiting Periods

Vehicles with and without driver's airbag:

If 1-component screen adhesive is used:

Put vehicle into operation at the earliest after 2 hours.

The adhesive is hardened after 36 hours.

Hardening is caused by air humidity (physical curing).

If 2-component adhesive set is used:

Vehicle is unconditionally ready for operation after 1 hour.

Hardening is caused by a chemical reaction.

Vehicles with driver's and co-driver's airbags:

If 1-component or 2-component adhesives are used:

Allow vehicle to stand overnight.